Haynes Chevrolet Corsica & Beretta Automotive Repair Manual 1563921332, 9781563921339

Citation preview

|

. A C I S R O C

BERETTA

1995 All models _ [el ih

Automotive Repair Manual

Chevrolet Corsica & Beretia

Automotive Repair Manual by Jon LaCourse and John H Haynes Member of the Guild of Motoring Writers

Models covered: Chevrolet Corsica and Beretta — all models

Ue 1987

1995

ee

(10W6 — 1628) 4 AUTS

F)s TIVE

me-CIESSS es

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

MEMBE

ABCOE

Acknowledgements We are grateful for the help and cooperation of the Chevrolet Motor Division of General Motors Corporation for assistance with technical information, certain illustrations and vehicle photos. The Champion Spark Plug Company supplied the illustrations of various spark plug conditions. Technical writers who contributed to this project include Larry Warren, Mike Stubblefield, Robert Maddox and Ken Freund. Special thanks to Jim Feuling of Feuling Engineering, Inc. of Ventura, California, for supplying the Quad-4 engine used for the photographs in Chapter 2. ©

Haynes North America, Inc. 1990, 1992, 1994 With permission from J. H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series

Printed in the USA

:

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 133 2 Library of Congress Catalog Card Number 94-073118 While every attempt is made to ensure that the information in this manualis correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Contents Introductory pages About this manual Introduction to the Chevrolet Corsica & Beretta Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting Jacking and towing Automotive chemicals and lubricants Safety first! Conversion factors Troubleshooting

6 6 7 10 10 17 18 19 20 21 22

Chapter 1 Tune-up and routine maintenance

29

Chapter 2 Part A 2.0/2.2 liter four-cylinder overhead valve engines

59

Chapter 2 Part B 2.3 liter four-cylinder (Quad-4) engine

73

Chapter 2 Part C V6 engines

93

Chapter 2 Part D General engine overhaul procedures

109

2A 2B 2C 2D

Chapter 3 Cooling, heating and air conditioning systems

149

Chapter 4 Fuel and exhaust systems

163

Chapter 5 Engine electrical systems

179

Chapter 6 Emissions control systems

187

Chapter 7 PartA Manual transaxle

203

7A

216

7B

. Chapter 7 Part B Automatic transaxle

Chapter 8 Clutch and driveaxles

229

Chapter 9 Brakes

244

Chapter 10 267

10

288

11

Chassis electrical system

305

12

Wiring diagrams

319

Index

353

Suspension and steering systems

Chapter 11 Body

Chapter 12

Chevrolet Corsica

jajosunayuyD epeseg NLD

ers

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. Itcan do so in several ways. Itcan help you decide what work must be done, even if you choose to have it done by a dealer service department

or arepair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many

simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs.

An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into

numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered section you will be referred to any illustrations which apply to the procedures in that section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated.

Whenit’s necessary to referto another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, “see Section 8” means in the same Chapter. References to the left or right side of the vehicle assume you are sitting in the driver’s seat, facing forward. Even though we have prepared this manual with extreme care, neither

the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning Is found. Not heeding a Warning can result in personal injury.

Introduction to the Chevrolet Corsica and Beretta The Chevrolet Corsica four-door sedan and Beretta two-door coupe are popular mid-size, front wheel drive vehicles first introduced for the 1987 model year. Engines used in these vehicles include the 2.0 and 2.2 liter overhead valve (OHV) four-cylinder, the 2.3 liter overhead cam (OHC) Quad-4 fourcylinder (later years only), the 2.8 liter V6 and the 3.1 liter V6, which is an enlarged version of the 2.8 liter engine. Throttle body injection (TBI) is used on the overhead valve four-cylinder engines through 1991, while multi-port fuel injection is standard on the Quad-4, 1992 and later 2.2L four-cylinder engines and all V6 engines.

The engine drives the front wheels through either a manual or automatic transaxle via unequal length driveaxles. The power assisted rack and pinion steering is mounted behind the engine. The front suspension is composed of MacPherson struts, three-point control arms and a stabilizer bar. The rear suspension is semi-independent, made up of a solid axle with trailing arms, a stabilizer bar, coil springs and shock absorbers. ~ The brakes are disc at the front and drum at the rear with power assist as standard equipment. An Anti-lock Brake System (ABS) is available as an option on some models.

©

Vehicle identification numbers Modifications are a continuing and unpublicized part of vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly identify the component required.

Vehicle Identification Number (VIN) This very important identification number is stamped on a plate attached to the left side of the dashboard and is visible through the driver’s side of the windshield (see illustration). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains valuable information such as where and when the vehicle was manufactured, the model year

and the body style.

Body identification plate This metal plate is located on the top side of the radiator support. Like the VIN, it contains important information concerning the production of the vehicle as well as information about how the vehicle came equipped from

the factory. It’s especially useful for matching the color and type of paint during repair work.

Service parts identification label This label is located in the trunk (see illustration). It lists the VIN number, wheelbase, paint number, options and other information specific to the vehicle it’s attached to. Always refer to this label when ordering parts.

The Vehicle Identification Number (VIN) is on a_

plate attached to the top of the dashboard on the driver’s side of the vehicle — it can be seen

through the windshield |

The Service parts identification label is located in the trunk (arrow) )

8

Vehicle identification numbers

2.0/2.2 liter four-cylinder engine number locations 1 VIN number 2 Engine code

2.3 liter four-cylinder (Quad-4) engine number location 1

Partial VIN number

S

2.3 liter four-cylinder (Quad-4) engine code label location

1

Traceability label

2

Verification label

3

number

stamped onapadon the radiator side, at the rear of the block (see illustra-

YL

7

V6 engine number locations 71»

on 2.0/2.2 liter four-cylinder engines is

aS 4

be ry:

We

Unit number

Engine identification numbers The engine code

\ k S

Starter motor

'

We

s

o

*>

2

2

VIN number

Engine code

TRANSAXLE 1.D. NAMEPLATE

§000001 —— SEQUENCE LAST

NUMBER

NUMBER

OF CALENDAR

YEAR

tion). The 2.3 liter OHC (Quad-4) engine VIN number is stamped into the

rear of the block, near the starter motor (see illustration). The Quad-4 en_ gine also has acode label attached to the rear edge of the timing belt housing (see illustration). On V6 engines, the code number is found on a pad on the rear of the block, just above the starter motor (see illustration).

Manual transaxle number The VIN number on the Isuzu 76 mm five-speed transaxle is stamped into either the front edge or the upper edge of the case, where it joins the bellhousing (see illustration). The Muncie transaxle has an adhesivebacked identification label attached to the rear of the case and an ID

Isuzu transaxle number locations

1

VIN number

2

Optional VIN location

Vehicle identification numbers

MODEL YEAR (9 = 1989)

9

BUILD DAY OF MONTH 01 = 1ST DAY 15 = 15TH DAY

VIN

BUILD MONTH A = JANUARY B = FEBRUARY C = MARCH

TRANSAXLE

NAMEPLATE

LOCATION

~ OPTIONAL VIN LOCATION

1.D.

THM 125/125-C TRANSAXLE |.D. NAMEPLATE LOCATION

SEPTEMBER OCTOBER NOVEMBER DECEMBER

JULIAN

DATE

TRANSAXLE 1.0. STAMP LOCATION

TRANSAXLE IDENTIFICATION TAG LOCATION 1985) (88 = 1988 etc)

THM 125/125-C TRANSAXLE 1.D. NAMEPLATE YPSILANTI, MICHIGAN

XXX wduasoan MH

MUNCIE

SHIFT A = FIRST SHIFT 8 = SECOND SHIFT Cis THIRD SHIFT

JULIAN DATE OR DAY OF THE YEAR

(3 (4 G (8

= 1983) = 1984) = 1885) = 1988 etc)

Muncie transaxle number locations

THM 125/125-C TRANSAXLE I.D. NAMEPLATE WINDSOR, CANADA Automatic transaxle number locations

number stamped into the front (see illustration). On the Getrag fivespeed transaxle, the VIN is on a pad at the front (radiator) side of the case edge, near the bellhousing (seeillustration). If the transaxle label is missing or unreadable, use the Service parts identification label to determine which transaxle was installed at the factory.

Automatic transaxle number The automatic transaxle nameplate/VIN number is attached to the upper surface of the case, near the rear (see illustration).

Vehicle Emissions Control Information label . Getrag transaxle number locations 71

VIN number

2

Optional VIN location

This label is found in the engine compartment, usually on the air cleaner intake (See Chapter 6 for an illustration of the label).

Buying parts Replacement parts are available from many sources, which generally

fall into one of two categories — authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned parts on an exchange basis, which can

save a considerable amount of money. Discount auto parts stores are oftenvery good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general accessories, have con-

venient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: |f the vehicle is still covered under warranty, be sure that any replacement parts purchased — regardless of the source — do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis

numbers available and, if possible, take the old parts along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.

Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasten-

ers should be clean and straight, with undamaged threads and undamaged corners.on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts

with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should betreated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works quite well. After applying the rust penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose. Most automotive machine shops can perform this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use alockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic.

Maintenance techniques, tools and working facilities

11

Fastener sizes

x 25 metric bolt is 12 mm in diameter, has a thread pitch of 1.75 mm (the

used ona standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to it. The greater the number of slashes, the greater the strength ofthe bolt. Grades 0 through 5 are commonly used on automobiles. Metric bolts have a property class (grade) number, rather than a slash, molded into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and 10.9 are commonly used on au-

distance between threads) and is 25 mm long. The two bolts are nearly

tomobiles.

identical, and easily confused, but they are not interchangeable.

Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped into one side, while metric nuts are marked with a number. The greater the number of dots, or the higher the number, the greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade.

For anumber of reasons, automobile manufacturers are making wider

and wider use of metric fasteners. Therefore, it is important to be able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged. All bolts, whether standard or metric, are sized according to diameter, thread pitch and length. For example, a standard 1/2 — 13 x 1 bolt is 1/2

inch in diameter, has 13 threads per inch andis 1 inchlong. AnM12—1.75

In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard bolt head is measured in inches, while the same dimension on a metric bolt is sized in millimeters (the same is true for nuts). As a result,

a standard wrench

should not be used on a metric bolt anda metric wrench should not be

Grade

1 or 2

Bolt strength markings (top — standard/SAE/USS; bottom — metric)

Grade

ws

Standard hex nut strength markings

co

Metric hex nut strength markings

eri)

Metric stud length markings

12

Maintenance techniques, tools and working facilities

It should be noted that many fasteners, especially Grades 0 through 2, have no distinguishing marks on them. When such is the case, the only way to determine whether it is standard or metric is to measure the thread pitch or compare it to a known fastener of the same size.

Standard fasteners are often referred to as SAE, as opposed to metric. However, it should be noted that SAE technically refers to a non-metric fine thread fastener only. Coarse thread non-metric fasteners are referred to as USS sizes. Since fasteners of the same size (both standard and metric) may have different strength ratings, be sure to reinstall any bolts, studs or nuts re-

moved from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a strength rat-

ing equal to or greater than the original.

Tightening sequences and procedures Mostthreaded fasteners should be tightened to a specific torque value (torque is the twisting force applied to a threaded component such as a nut or bolt). Overtightening the fastener can weaken it and cause it to break, while undertightening can cause it to eventually come loose. Bolts, screws and studs, depending on the material they are made of and their thread diameters, have specific torque values, many of which are noted in the Specifications at the beginning of each Chapter. Be sure to follow the torque recommendations closely. For fasteners not assigned a specific torque, ageneral torque value chartis presented here as aguide. These torque values are for dry (unlubricated) fasteners threaded into steel or cast iron (not aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be

Metric thread sizes ee a2 Rar hed arene yy aoe Bes es

TB.

Ft-lbs

Nm

6 to9 14 to 28 to 50 to 80 to

9to 12 19 to 28 38 to 54 68 to 96 109 to 154

21 40 71 140

6S ont oe aioe aee pe ae a eerie etait tats Baits ea ee Nee Re ae

5to8 12 to 18 22 to 33 25 to 35

7 to 10 17 to 24 30 to 44 34 to 47

Ser ee sear Geo Retere Make Feeds Shek:

6 to 9 12 to 18 14 to 20 22 to 32 27 to 38 40 to 55 40 to 60 55 to 80

9to 12 17to 24 19 to 27 30 to 43 37 to 51 55 to 74 55 to 81 75 to 108

Cc

Standard (SAE and USS) bolt dimensions/grade marks

Metric bolt dimensions/grade marks

G_

Grade marks (bolt length)

Property class (bolt strength)

L

Length (in inches)

T D

Thread pitch (number of threads per inch) Nominal diameter (in inches)

Length (in millimeters) Thread pitch (distance between threads in millimeters) OyHrD Diameter

Maintenance techniques, tools and working facilities

13

applied to it. The figures listed here are approximate for Grade 2 and

Hose removal tips

Grade 3 fasteners. Higher grades can tolerate higher torque values.

Warning: /f the vehicle is equipped with air conditioning, do not disconnectany of the A/C hoses without first having the system depressurized by a dealer service department or a service station.

Fasteners laid out in a pattern, such as cylinder head bolts, oil pan bolts, differential cover bolts, etc., must be loosened or tightened in sequence to avoid warping the component. This sequence will normally be

shown in the appropriate Chapter. If a specific pattern is not given, the following procedures can be used to prevent warping. Initially, the bolts or nuts should be assembled finger-tight only. Next, they should be tightened one full turn each, in a criss-cross or diagonal

pattern. After each one has been tightened one full turn, return to the first one and tighten them all one-half turn, following the same pattern. Finally, tighten each of them one-quarter turn at a time until each fastener has been tightened to the proper torque. To loosen and remove the fasteners, the procedure would be reversed.

Component disassembly Component disassembly should be done with care and purpose to help ensure that the parts go back together properly. Always keep track

of the sequence in which parts are removed. Make note of special characteristics or marks on parts that can be installed more than one way, such as a grooved thrust washer on a shaft. It is a good idea to lay the disassembled parts out on aclean surface in the order that they were removed. It may also be helpful to make sketches or take instant photos of compo-

nents before removal. i When removing fasteners from a component, keep track of their locations. Sometimes threading a bolt back in a part, or putting the washers and nut back ona stud, can prevent mix-ups later. If nuts and bolts cannot be returned to their original locations, they should be kept in a compartmented box or a series of small boxes. A cupcake or muffin tin is ideal for

Hose removal precautions closely parallel gasket removal precau-

tions. Avoid scratching or gouging the surface that the hose mates against or the connection may leak. This is especially true for radiator hoses. Be-

cause of various chemical reactions, the rubber in hoses can bond itself ‘to the metal spigot that the hose fits over. To remove a hose, first loosen

the hose clamps that secure it to the spigot. Then, with slip-joint pliers, grab the hose at the clamp and rotate it around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone or other lubricants will ease removal if they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inside of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced with a new one any-

way), the rubber can be slit with a knife and the hose peeled from the spigot. If this must be done, be careful that the metal connection is not damaged. If a hose clamp is broken or damaged, do not reuse it. Wire-type clamps usually weaken with age, so it is a good idea to replace them with screw-type clamps whenever a hose is removed.

Tools A selection of good tools is a basic requirement for anyone who plans to maintain and repair his or her own vehicle. For the owner who has few

tools, the initial investment might seem high, but when compared to the spiraling costs of professional auto maintenance and repair, it is a wise one.

this purpose, since each cavity can hold the bolts and nuts from a particu-

lar area (i.e. oil pan bolts, valve cover bolts, engine mount bolts, etc.). A pan of this type is especially helpful when working on assemblies with very small parts, such as the carburetor, alternator, valve train or interior dash

and trim pieces. The cavities can be marked with paint or tape to identify the contents. Whenever wiring looms, harnesses or connectors are separated, it is a good idea to identify the two halves with numbered pieces of masking tape so they can be easily reconnected.

Gasket sealing surfaces Throughout any vehicle, gaskets are used to seal the mating surfaces between two parts and keep lubricants, fluids, vacuum or pressure con-

tained in an assembly. Many times these gaskets are coated with a liquid or paste-type gasket sealing compound before assembly. Age, heat and pressure can sometimes cause the two parts to stick together so tightly that they are very difficult to separate. Often, the assembly can be loosened by striking it with a soft-face hammer near the mating surfaces. A regular hammer can be used if a block of wood is placed between the hammer and the part. Do not hammer on cast parts or parts that could be easily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed. Avoid using a screwdriver or bar to pry apart an assembly, as they can easily mar the gasket sealing surfaces of the parts, which must remain smooth. If prying is absolutely necessary, use an old broom handle, but keep in mind that extra clean up will be necessary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated with a special chemical to soften it so it can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is recommended because it is usually softer than the surfaces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire brush, but regardless of the method used, the mating surfaces must be left clean and smooth. If for some reason the gasket surface is gouged, then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components. For most applications, a nondrying (or semi-drying) gasket sealer should be used.

Micrometer set

Dial indicator set

14

Maintenance techniques, tools and working facilities

Hand-operated vacuum pump

Timing light

Compression gauge with spark plug

General purpose puller

hole adapter

Hydraulic lifter removal tool

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

Ring removal/installation tool

Maintenance techniques, tools and working facilities

Ring compressor

Brake cylinder hone

_

15

Brake hold-down spring tool

Clutch plate alignment tool

Tohelp the owner decide which tools are needed to perform the tasks

detailed in this manual, the following tool lists are offered: Maintenance and minor repair, Repair/overhaul and Special. The newcomer to practical mechanics should start off with the maintenance and minor repair tool kit, which is adequate for the simpler jobs performed on a vehicle. Then, as confidence and experience grow, the owner can tackle more difficult tasks, buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and overhaul tool set. Over a period of time, the experienced do-it-yourselfer willassemble a tool set complete enough for most repair and overhaul procedures and will add tools from the special category when itis felt that the expense is justified by the frequency of use. Maintenance and minor repair tool kit The tools in this list should be considered the minimum required for performance of routine maintenance, servicing and minor repair work. We

recommend the purchase of combination wrenches (box-end and openend combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench.

Combination wrench set (1/4-inch to 1 inch or 6 mm to 19 mm) Adjustable wrench, 8 inch Spark plug wrench with rubber insert Spark plug gap adjusting tool Feeler gauge set Brake bleeder wrench Standard screwdriver (5/16-inch x 6 inch)

Tap and die set

Battery post and cable cleaning tool Oil filter wrench

Funnel (medium size) Safety goggles Jackstands(2) Drain pan

Note: /f basic tune-ups are going to be part of routine maintenance, it will be necessary to purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely neces-

sary for tuning most vehicles properly. Repair and overhaul tool set These tools are essential for anyone who plans to perform major repairs and aren addition to those in the maintenance and minor repair tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because of their versatility, especially when various extensions and drives are available. We recommend the 1/2-inch drive over the 3/8-inch drive. Although the larger drive is bulky and more expensive, it has the capacity of accepting a very wide range of large sockets. Ideally, however, the mechanic should have a 3/8-inch drive set and a 1/2-inch drive set. Socket set(s)

Reversible ratchet Extension — 10 inch

Phillips screwdriver (No. 2 x 6 inch)

Universal joint

Combination pliers — 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush

Torque wrench (same size drive as sockets) Ball peen hammer — 8 ounce Soft-face hammer (plastic/rubber) Standard screwdriver (1/4-inch x 6 inch) Standard screwdriver (stubby — 5/16-inch) Phillips screwdriver (No. 3 x 8 inch)

Phillips screwdriver (stubby — No. 2)

16

Maintenance techniques, tools and working facilities Pliers — vise grip

purchasing tools. If maintenance and minor repair is the extent of the work to be done, the purchase of individual tools is satisfactory. If, on the other

Pliers — lineman’s Pliers — needle nose

Pliers — snap-ring (internal and external) Cold chisel — 1/2-inch Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch)

Steel rule/straightedge — 12 inch Allen wrench set (1/8 to 3/8-inch or A selection of files

hand, extensive work is planned, it would be a good idea to purchase a modest tool set from one of the large retail chain stores. A set can usually be bought at a substantial savings over the individual tool prices, and they often come with a tool box. As additional tools are needed, add-on sets, individual tools and a larger tool box can be purchased to expand the tool selection. Building a tool set gradually allows the cost of the tools to be spread over a longer period of time and gives the mechanic the freedom to choose only those tools that will actually be used.

4mm to 10 mm)

Wire brush (large)

Jackstands (second set) Jack (scissor or hydraulic type) Note: Another tool which is often useful is an electric drill motor with a

chuck capacity of 3/8-inch and a set of good quality drill bits.

Special tools The tools in this list include those which are not used regularly, are expensive to buy, or which need to be used in accordance with their man-

ufacturer’s instructions. Unless these tools will be used frequently, it is not very economical to purchase many of them. A consideration would be to split the cost and use between yourself and a friend or friends. In addition, most of these tools can be obtained from a tool rental shop on.a temporary basis.

This list primarily contains only those tools and instruments widely available to the public, and not those special tools produced bythe vehicle manufacturer for distribution to dealer service departments. Occasionally, references to the manufacturer’s special tools are included in the text of

Tool stores will often be the only source of some of the special tools that are needed, but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers and sockets, because they won't last very long. The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools. Care and maintenance of tools Good tools are expensive, so it makes sense to treat them with respect. Keep them clean and in usable condition and store them properly when notin use. Always wipe off any dirt, grease or metal chips before putting them away. Never leave tools lying around in the work area. Upon completion of ajob, always check closely under the hood for tools thatmay

have been left there so they won't get lost during a test drive. © Some tools, such as screwdrivers, pliers, wrenches and sockets, can be hung on apanel mounted on the garage or workshop wall, while others should be kept in a tool box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or impact from other tools. When tools are used with care and stored properly, they will lasta very

long time. Even with the best of care, though, tools will wear out if used

this manual. Generally, an alternative method of doing the job without the

frequently. When a tool is damaged or worn out, replace it. Subsequent jobs will be safer and more enjoyable if you do.

special tool is offered. However, sometimes there is no alternative to their use. Where this is the case, and the tool cannot be purchased or bor-

Working facilities

rowed, the work should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor

Piston ring groove cleaning tool Piston ring compressor

If anyof suitdo not an en-

gine or doing major repairs outside. It is recommended, however, that the

Piston ring installation tool

overhaul or repair be completed under the cover of a roof. Aclean, flat workbench or table of comfortable working heightis anvabsolute necessity. The workbench should be equipped with a vise that has a jaw opening of at least four inches. As mentioned previously, some clean, dry storage space is also required for tools, as well as the lubricants, fluids, cleaning solvents, etc.

Cylinder compression gauge

Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge

Micrometers and/or dial calipers Hydraulic lifter removal tool Balljoint separator

which soon become necessary.

Universal-type puller Impact screwdriver Dial indicator set Stroboscopic timing light (inductive pick-up) Hand operated vacuum/pressure pump

Tachometer/dwell meter Universal electrical multimeter Cable hoist Brake spring removal and installation tools Floor jack

Buying tools For the do-it-yourselfer who is just starting to get involved in vehicle maintenance and repair, there are

Not to be overlooked when discussing tools is the workshop. thing more than routine maintenance is to be carried out, some sort able work area is essential. It is understood, and appreciated, that many home mechanics have a good workshop or garage available, and end up removing

a number of options available when

Sometimes waste oil and fluids, drained from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, pour

the used fluids into large containers, seal them with caps and take them to an authorized disposal site or recycling center. Plastic jugs, such as old antifreeze containers, are ideal for this purpose. Always keep a supply of old newspapers and clean rags available. Old towels are excellent for mopping up spills. Many mechanics use rolls of paper towels for most work because they are readily available and disposable. To help keep the area under the vehicle clean, alarge cardboard box can be cut open and flattened to protect the garage or shop floor. Whenever working over a painted surface, such as when leaning over a fender to service something under the hood, always cover it with an old blanketorbedspread to protect the finish. Vinyl covered pads, made especially for this purpose, are available at auto parts stores.

Booster battery (jump) starting Observe these precautions when using a booster battery to start a vehicle: a) Before connecting the booster battery, make sure the ignition switch is in the Off position. b) Turn off the lights, heater and other electrical loads.

c) Your eyes should be shielded. Safety goggles are a good idea. d) Make sure the booster battery is the same voltage as the dead one in the vehicle. e) The two vehicles MUST NOT TOUCH each other! f) Make sure the transmission is in Neutral (manual) or Park (auto-

Connect the red jumper cable to the positive (+) terminals of each bat-

tery. Connect one end of the black jumper cable to the negative (—) terminal of the booster battery. The other end of this cable should be connected to a good ground on the vehicle to be started, such as a bolt or bracket on the engine block (see illustrations). Make sure the cable will not come

into contact with the fan, drivebelts or other moving parts of the engine. Start the engine using the booster battery, then, with the engine running at idle speed, disconnect the jumper cables in the reverse order of

connection.

matic).

g) If the booster battery is not a maintenance-free type, remove the vent caps and lay a cloth over the vent holes.

Adapters designed to make jumper cable connections to side terminal batteries safer and easier are available at auto parts stores

Make the booster battery cable connections in the numerical order shown (note that the negative cable of the booster battery is NOT attached to the negative terminal of the dead battery)

Jacking and towing Jacking

Towing

Warning: The jack supplied with the vehicle should only be used for raising the vehicle when changing a tire or placing jackstands under the frame.

These vehicles can be towed with all four wheels on the ground, provided that speeds don’t exceed 35 mph and the distance is less than 50

Never work under the vehicle or start the engine while the jack is being

miles, otherwise transaxle damage can result.

used as the only means of support.

Equipment specifically designed for towing should be used. It must be attached to the main structural members of the vehicle, not the bumpers or brackets. Safety is a major consideration when towing and all applicable state and local laws must be obeyed. A safety chain must be used at all times. The parking brake must be released and the transaxle must be in Neutral. The steering must be unlocked (ignition switch in the Off position). Re-

The vehicle must be on a level surface with the wheels blocked and the transaxle in Park (automatic) or Reverse (manual). Apply the parking brake if the front of the vehicle must be raised. Make sure no one is in the vehicle as it’s being raised with the jack.

Remove the jack, lug nut wrench and spare tire (if needed) from the trunk. If a tire is being replaced, use the lug wrench to remove the wheel cover. Warning: Wheel covers may have sharp edges — be very careful not to cut yourself. Loosen the lug nuts one-half turn, but leave them in place until the tire is raised off the ground. Note: Some models have nylon lug nut caps. Loosen them very carefully with the wrench, then remove them by hand before loosening the lug nuts. Also, some vehicles have one locking lug nut that must be loosened with a special anti-theft wrench adapter. Position the jack under the side of the vehicle at the indicated jacking

point. There’s a front and rear jacking point’on each side of the vehicle (see illustration). Turn the jack handle clockwise until the tire clears the ground. Remove the lug nuts and pull the tire off. Clean the mating surfaces of the hub and wheel, then install the spare. Replace the lug nuts with the bevelled edges facing in and tighten them snugly. Don’t attempt to tighten them completely until the vehicle is lowered or it could slip off the jack.

member that power steering and power brakes won't work with the engine off.

225 mm 9 INCHES

175 mm 7 INCHES JACK LIFTHEAD MUST MATE WITH VEHICLE NOTCHES CORRECTLY OR DAMAGE IS LIKELY TO OCCUR.

p) L-—a

€ NOTCHES,

FRONT

Turn the jack handle counterclockwise to lower the vehicle. Remove the jack and tighten the lug nuts in acriss-cross pattern. If possible, tighten the nuts with a torque wrench (see Chapter 1 for the torque figures). If you don’t have access to a torque wrench, have the nuts checked by a service station or repair shop as soon as possible. Caution: The compact spare included with these vehicles is intended for temporary use only. Have the

tire repaired and reinstall it on the vehicle at the earliest opportunity and don’t exceed 50 mph with the spare tire on the car. Install the wheel cover or nylon lug nut caps, then stow the tire, jack and wrench and unblock the wheels.

Jacking points

Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and

Heat-sink greaseis a special electrically non-conductive grease that is used for mounting electronic ignition modules where it is essential that heat is transferred away from the module.

protective sprays for rubber, plastic and vinyl.

Sealants

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum,

varnish and carbon. Most carburetor cleaners leave a dry-type lubricant film which will not harden or gum up. Because of this film it is not recommended for use on electrical components. Brake system cleaner is used to remove grease and brake fluid from the brake system, where clean surfaces are absolutely necessary. It leaves no residue and often eliminates brake squeal caused by contaminants.

Electrical cleaner removes oxidation, corrosion and carbon deposits from electrical contacts, restoring full current flow. It can also be used to

clean spark plugs, carburetor jets, voltage regulators and other parts where an oil-free surface is desired.

RTV sealantis one of the most widely used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills surface

irregularities, remains flexible, doesn’t shrink, is relatively easytoremove, and is used as a supplementary sealer with almost all low and medium temperature gaskets. Anaerobic sealantis much like RTV in that it can be used either to seal gaskets orto form gaskets by itself. It remains flexible, is solvent resistant and fills surface imperfections. The difference between an anaerobic sea-

lant and an RTV-type sealant is in the curing. RTV cures when exposed to air, while an anaerobic sealant cures only inthe absence of air. This means

that an anaerobic sealant cures only after the assembly of parts, sealing them together. Thread and pipe sealant is used for sealing hydraulic and pneumatic

Demoisturants remove water and moisture from electrical components such as alternators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive, non-corrosive and non-flammable.

fittings and vacuum lines. It is usually made froma teflon compound, and comes in a spray, a paint-on liquid and as a wrap-around tape.

Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and, depending on the type, are rinsed off either with water or solvent.

Chemicals

Lubricants Motor oilis the lubricant formulated for use in engines. It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) from 5 to 80. The recommended weight of the oil depends on the season, temperature and the demands on the engine. Light oil is used in cold climates and

under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights from 5W-20 to 20W-50. Gear oil is designed to be used in differentials, manual transmissions and other areas where high-temperature lubrication is required.

Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered, such as for wheel bearings,

balljoints, tie-rod ends and universal joints. High-temperature wheel bearing greases designed to withstand the extreme temperatures encountered by wheel bearings in disc brake

equipped vehicles. It usually contains molybdenum disulfide (moly), which is a dry-type lubricant. White grease is a heavy grease for metal-to-metal applications where water is a problem. White grease stays soft under both low and high temperatures (usually from —100 to +190-degrees F), and will not wash off or

dilute in the presence of water. Assembly lube is a special extreme pressure lubricant, usually containing moly, used to lubricate high-load parts (such as main and rod bearings and cam lobes) for initial start-up of

anew engine. The assembly lube

lubricates the parts without being squeezed out or washed away until the engine oiling system begins to function.

Silicone lubricants are used to protect rubber, plastic, vinyl and nylon parts. . Graphite lubricants are used where oils cannot be used due to con-

Anti-seize compoundprevents seizing, galling, cold welding, rust and corrosion in fasteners. High-temperature anti-seize, usually made with copper and graphite lubricants, is used for exhaust system and exhaust manifold bolts. Anaerobic locking compounds are used to keep fasteners from vi-

brating or working loose and cure only after installation, in the absence of air. Medium strength locking compound is used for small nuts, bolts and screws that may be removed later. High-strength locking compound is for

large nuts, bolts and studs which aren't removed on a regular basis. Oil additives range from viscosity index improvers to chemical treatments that claim to reduce internal engine friction. It should be noted that

most oil manufacturers caution against using additives with their oils. Gas additives perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that build up on carburetor, fuel injection and intake parts. They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers. Some additives contain upper cylinder lubricants for

valves and piston rings, and others contain chemicals to remove condensation from the gas tank.

Miscellaneous Brake fluidis specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake systems. Care must be taken so this fluid does not come in contact with painted surfaces or plastics. An opened container should always be resealed to prevent contamination by water or dirt. Weatherstrip

adhesive

is used to bond

weatherstripping

around

doors, windows and trunk lids. It is sometimes used to attach trim pieces. Undercoating is a petroleum-based, tar-like substance that is designed to protect metal surfaces on the underside of the vehicle from corrosion. It also acts as asound-deadening agent by insulating the bottom of

the vehicle. Waxes and polishes are used to help protect painted and plated surfaces from the weather. Different types of paint may require the use of dif-

tamination problems, such as inlocks. The dry graphite will lubricate metal

ferent types of wax

parts while remaining uncontaminated by dirt, water, oil or acids. Itis elec-

abrasive cleaner to help remove the top layer of oxidized (dull) paint on older vehicles. In recent years many non-wax polishes that contain a wide

trically conductive and will not foul electrical contacts in locks such as the ignition switch. ' Moly penetrants loosen and lubricate frozen, rusted and corroded fasteners and prevent future rusting or freezing.

and polish. Some

polishes utilize a chemical

or

variety of chemicals such as polymers and silicones have been introduced. These non-wax polishes are usually easiertoapply and last longer

than conventional waxes and polishes.

Safety first! Regardless of how enthusiastic you may be about getting on with the job at hand, take the time to ensure that your safety is not jeopardized. A moment's lack of attention can result in an accident, as can failure to observe certain simple safety precautions. The possibility of an accident will always exist, and the following points should not be considered a comprehensive list of all dangers. Rather, they are intended to make you aware of the risks and to encourage a safety conscious approach to all work you

carry out on your vehicle.

.

Essential DOs and DON’Ts DON'T rely on a jack when working under the vehicle. Always use ap-

proved jackstands to support the weight of the vehicle and place them under the recommended lift or support points. DON’T attempt to loosen extremely tight fasteners (i.e. wheel lug nuts) while the vehicle is on a jack — it may fall. DON’T start the engine without first making sure that the transmission is in Neutral (or Park where applicable) and the parking brake is set. DON’T remove the radiator cap from a hot cooling system — let it cool or

cover it with a cloth and release the pressure gradually. DON’T attempt to drain the engine oil until you are sure it has cooled to the point that it will not burn you. DON’T touch any part of the engine or exhaust system until it has cooled

sufficiently to avoid burns. DON’T siphon toxic liquids such as gasoline, antifreeze and brake fluid by mouth, or allow them to remain on your skin. DON’T inhale brake lining dust—itis potentially hazardous (see Asbestos below)

DON’T allow spilled oil or grease to remain on the floor —wipe it up before someone slips on it. DON’T use loose fitting wrenches or other tools which may slip and cause injury. DON’T push on wrenches when loosening or tightening nuts or bolts. Always try to pull the wrench toward you. If the situation calls for pushing the wrench away, push with an open hand to avoid scraped knuckles if the wrench should slip.

DON’T attempt to lift aheavy component alone—get someone to help you. DON’T rush or take unsafe shortcuts to finish a job. DON’T allow children or animals in or around the vehicle while you are working on it. DO wear eye protection when using power tools such as a drill, sander, bench grinder, etc. and when working under a vehicle.

DO keep loose clothing and long hair well out of the way of moving parts. DO make sure that any hoist used has a safe working load rating adequate for the job.

DO get someone to check on you periodically when working alone ona

Fire Rememberat all times that gasoline is highly flammable. Never smoke or have any kind of open flame around when working on a vehicle. But the risk does not end there. A spark caused by an electrical short circuit, by

two metal surfaces contacting each other, or even by static electricity built up in your body under certain conditions, canignite gasoline vapors, which in a confined space are highly explosive. Do not, under any circumstances, use gasoline for cleaning parts. Use an approved safety solvent.

Always disconnect the battery ground (—) cable at the battery before working on any part of the fuel system or electrical system. Never risk spilling fuel on a hot engine or exhaust component.

It is strongly recommended that a fire extinguisher suitable for use on fuel and electrical fires be kept handy in the garage or workshop at all times. Never try to extinguish a fuel or electrical fire with water. Fumes Certain fumes are highly toxic andcan quickly cause unconsciousness and even death if inhaled to any extent. Gasoline vapor falls into this category, as do the vapors from some cleaning solvents. Any draining or pouring of such volatile fluids should be done in a well ventilated area. When using cleaning fluids and solvents, read the instructions on the container carefully. Never use materials from unmarked containers. Never run the engine in an enclosed space, such as agarage. Exhaust

fumes contain carbon monoxide, which is extremely poisonous. If you need to run the engine, always do so in the open air, or at least have the rear of the vehicle outside the work area. If you are fortunate enough to have the use of an inspection pit, never drain or pour gasoline and never run the engine while the vehicle is over the pit. The fumes, being heavier than air, will concentrate in the pit with possibly lethal results.

The battery Never create a spark or allow a bare light bulb near a battery. They normally give off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery ground (—) cable at the battery before working on the fuel or electrical systems. ' If possible, loosen the filler caps or cover when charging the battery from an external source (this does not applytosealed or maintenancefree batteries). Do not charge at an excessive rate or the battery may burst. Take care when adding water to a non maintenance-free battery and when carrying a battery. The electrolyte, even when diluted, is very corrosive and should not be allowed to contact clothing or skin. Always wear eye protection when cleaning the battery to prevent the caustic deposits from entering your eyes.

vehicle.

DO carry out work in a logical sequence and make sure that everything is correctly assembled and tightened. DO keep chemicals and fluids tightly capped and out of the reach of children and pets.

Household current When using an electric power tool, inspection light, etc., which operates on household current, always make sure that the tool is correctly connected to its plug and that, where necessary, it is properly grounded. Do

DOremember that your vehicle's safety affects that of yourself and others. If in doubt on any point, get professional advice.”

not use such items in damp conditions and, again, do not create a spark or apply excessive heat in the vicinity of fuel or fuel vapor.

Asbestos

Secondary ignition system voltage

Certain friction, insulating, sealing, and other products —such as brake linings, brake bands, clutch linings, torque converters, gaskets, etc. —con-

A severe electric shock can result from touching certain parts of the ignition system (such as the spark plug wires) when the engine is running or being cranked, particularly if components are damp or the insulation is defective. In the case of an electronic ignition system, the secondary system voltage is much higher and could prove fatal.

tain asbestos. Extreme care mustbe taken to avoid inhalation of dust from such products since it is hazardous to health. \fin doubt, assume that they

do contain asbestos.

Conversion

factors

Length (distance) Inches (in)

X

25.4

=Millimetres

X

0.0394

Feet (ft)

X

0.305

= Metres (m)

(mm)

X

3.281

=Inches

= Feet (ft)

(in)

Miles

X

1.609

= Kilometres (km)

X

0.6621

=Miles

Volume (capacity) Cubic inches (cu in; in’) Imperial pints (Imp pt) Imperia! quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

X xX xX) X X X xX X

16.387 = Cubic centimetres (cc; cm’) 0.568 = Litres (|) 12137 = Litres (I) 1.201 =US quarts (US qt) 0.946 =Litres (|) 4.546 = Litres (I) 1.201 =US gallons (US gal) 3.785 =Litres (I)

x x x X x x X X

0.061 1.76 0.88 0.833 1.057 0.22 0.833 0.264

= Cubic inches (cu in; in’) = Imperial pints (Imp pt) = Imperial quarts (Imp qt) =Imperial quarts (Imp qt) =US quarts (US qt) = Imperial gallons (Imp gal) =Imperial gallons (Imp gal) =US gallons (US gal)

X xX

28.35 0.454

=Grams (g) = Kilograms (kg)

x X

0.035 2.205

= Ounces (oz) = Pounds (Ib)

x X xX

0.278 4.448 0.1.

=Newtons (N) = Newtons (N) =Kilograms-force

(kgf; kg)

x X x

3.6 0.225 9.81

= Ounces-force (ozf; oz) = Pounds-force (Ibf; Ib) = Newtons (N)

xX

0.070

= Kilograms-force

per square

X

14.223

= -Pounds-force per square inch

X

14.696

= Pounds-force

Mass (weight) Ounces (oz) Pounds (Ib)

et

Force Ounces-force (ozf; oz) Pounds-force (Ibf; Ib) Newtons (N)

Pressure Pounds-force

per square inch

(psi; Ibf/in?; Ib/in?) Pounds-force

centimetre (kgf/cm?; kg/cm?)

per square inch

X

0.068

=Atmospheres

(atm)

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?; Ib/in?)

per square

inch

(psi; Ibf/in?; Ib/in?)

Pounds-force

per square inch

X

0.069

= Bars

x

14.5

= Pounds-force

per square inch

Pounds-force

per square inch

X

6.895

= Kilopascals (kPa)

x

0.145

=Pounds-force

per square inch

X

0.01

=Kilograms-force

x

98.1

(psi; Ibf/in?; |b/in)

(psi; Ibf/in?; |b/in?) Kilopascals (kPa)

per square

(psi; Ibf/in?; Ib/in)

(psi; Ibf/in?; |b/in?)

= Kilopascals (kPa)

centimetre (kgf/cm?; kg/cm?) Torque (moment of force) Pounds-force (Ibf in; Ib in) Pounds-force (Ibf in; Ib in) Pounds-force (Ibf in; Ib in) Pounds-force

inches

X

1.152

xX

0.868

0.113

= Kilograms-force centimetre (kgf cm; kg cm) =Newton metres (Nm)

x

8.85

X

0.083

= Pounds-force feet (Ibf ft; Ib ft)

x

12

feet (Ibf ft; Ib ft)

X

0.138

X

7.233

Pounds-force feet (Ibf ft; Ib ft) Newton metres (Nm)

xX X

1.356 0.102

= Kilograms-force metres (kgf m; kg m) = Newton metres (Nm) = Kilograms-force metres (kgf m; kg m)

= Pounds-force inches (Ibf in; Ib in) = Pounds-force inches (Ibf in; Ib in) = Pounds-force inches (Ibf in; Ib in) =Pounds-force feet (Ibf. ft; Ib ft)

inches

X

inches

X. X

0.738 9.804

=Pounds-force feet (Ibf ft; Ib ft) =Newton metres (Nm)

X

745.7

=Watts

xX

0.0013

X

1.609

= Kilometres per hour (km/hr; kph) X

Miles per gallon, Imperial (mpg)

X

0.354

= Kilometres per litre (km/|)

Miles per gallon, US (mpg)

X

0.425

= Kilometres per litre (km/I)

Power Horsepower

(hp)

(W)

=Horsepower

(hp)

Velocity (speed) Miles per hour (miles/hr; mph)

0.621

=Miles per hour (miles/hr; mph)

X

2.825

=Miles per gallon, Imperial (mpg)

X

2.352

=Miles per gallon, US (mpg)

Fuel consumption*

Temperature Degrees Fahrenheit

=

(°C x 1.8) + 32

Degrees Celsius (Degrees Centigrade; °C)

*/t is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (//100km), where mpg (Imperial) x 1/100 km = 282 and mpg (US) x 1/100 km = 235

= (°F - 32) x 0.56

Troubleshooting Contents

Symptom

Section

Engineibacktires isaemarina daeocte a suse mn rderra Nai eee Engine diesels (continues to run) after switching off ........... Engine hard tolstart whem/cold) ir... acl ter ciate exces eriets Engines hard:toistart:wihennOliy. mtenserets pretctelexevensteicorastiees teaver aici Enginie lacks: DOWED, ercicrrits ones ccine shetensrts a eye ea aeons waa Engine lopes while idling or idles erratically .................. Enginesmisses:atiidle'speed), |See) eat eye eas ee een there Engine misses throughout driving speed range ............... Enginejrotates buriwillimot! Starts teen. eee aes eae ciemtcet mene Engine runs with oil’pressure lighton .......3-......0-+.508Engine’ stalls ry sir crept cede inn stoulay SR pecha hems eectsreeyaanawedounreeceams eee

......................-

Engine stumbles on acceleration ...........--.--0002e ee eee Engine surges while holding accelerator steady .............. Engine will not rotate when attempting to start ...............

Oilipuddle:underengine:

2..\.jccsbly cece lstere Ahastexcrare aeeePony cee eaiens

Pinging or knocking engine sounds during acceleration OriUuphillinn esse ctoscesstre: enero tes 8 eee Starter motor noisy or excessively roughin engagement

ean .......

15 18 3 4 14 8 ¢) 10 2 17 13

6 11 12 1

7 16 5

Excessive TUCliCONSUMPTION NS araeteun tea soca ter acetone oir 22 Fuel'leakage‘and/or fuel Odor. 2.5.0). vec 28 iets ee bee oe 23

Cooling system ei skis santiirona a tereeinten ae Oe eoateed ele ae ae so sreccn myareietater crenata

28

ued ar

26

Internal: coolant'lGakagev asc. aasitocuneticn cheeteee hirano Overcoolings (sR. ly oa es eralo eas ele te tae aren ic ene

27 25

Overheating. Ae s0R. cysherth aie ceases canrettonaoeWaterers eats pe ae ta Poorcoolanticirculation “trons susacekertee cee at Taree

24 29

Clutch Clutch pedal stays on floor)

45

43 41

Noisy in:one: particular'gear.

42

Slips out'of gear Vibration.

- : ... san.

se

sos

2 ee

wo. a. 24 Sisco lees oe er

22. sek ee

ean

st aghe Peek pela

44 ee

rw)

Automatic transaxle Engine will start in gears other than Park or Neutral ........... Fluid'leakager 5) ik. cee ao ae ds oye acute eo) oe ah

50 46

General shift mechanism problems ................+++eee08 Transaxle fluid brown or has aburned smell .............-..-

48 47

Transaxle slips, shifts roughly, is noisy or has no drive in forward or reverse gears ...2 2 soo. oe oe oe Transaxle will not downshift with accelerator pedal

51

pressed to. the floor 220.08 bi.

ae aes oe

49

Driveaxles 52 53 54

Brakes 21 20

Fuel system

External coolantiieakages

fi. csi jce vee cya es «Gre averse os

Noisy. invall:g@arsy.. 63s 2 ed eose «ae an wun se ales er Noisy in Neutral with engine running ..........2...-.....-8-

wake. cite ceeels minestrone = 19

Voltage warning light fails to come on when key 1S LUPE GION iestastedin eo feytge Glkre ed Pneeel ce) SpA eaoR eames Voltage warning light fails to go out .....................05.

Coolant loss: 4.

Leaks lubricant.

Clicking noise In tUENS. 2. 50% os 0ls sale to ee Knock or clunk when accelerating after coasting .............. Shudder or vibration during acceleration .................4-.

Engine electrical system Battery willinotiholdiaicharge

Section

Manual transaxle

Engine and performance

Engine starts but stops immediately.

Symptom

242itaser

Ueecrarnte akontee eu meremnen

38

Clutch slips (engine speed increases with no increase

in vehicle speed)! ps ris. SOR Sota, aie I mehor ea oe Fluid in area of master cylinder dust cover andonpedal ....... Fiuid'onislave: cylinder: 1, =i 3. seer alent us eee eac eee Grabbing (chattering) as clutch is engaged ..................

35 31 32 36

High pedal effort ........ fol chore Nactane Guat2 Sumas Resa erae taan ear Ree Noise'in clutchparea:: wiser: sth): ao anata yon tows ednae eee

39 37

Pedal feels spongy when depressed

33

.........-.--5-2--0000+

Pedal travels to floor — no pressure or Veryilittle resistance weaie acne rat Mere sca segs ook nee eennca tet meine

30

Unable to'selechQeanSe

34

mime nti. .5 = Sane cleans ceestoerereus rene ene

Brake pedal feels spongy when depressed ..............-.-Brake pedal travels to the floor with little resistance ...........

62 63

Brake roughness or chatter (pedal pulsates) ................. Dragging! brakes: «sc see op at eae die es nes oe

57 60

Excessive brake pedaltravel ... 3. f..c)05.. cers.) 2 4 one Excessive pedal effort required to stop vehicle ...............

59 58

Grabbing or uneven braking action ..............0..0+-5e05 Noise (high-pitched squeal when the brakes are applied) .......

61 56

Parking|brake does:not hold \..2 0.52.52...» oe eee Vehicle pulls to one side during braking ...................-.-

64 55

Suspension and steering systems Abnormal or excessive tire wear ..........-.2.202 cence eens Abnormal:noise at the frontend ..... 2250... ::. . «5 serene

66 Aik

Cuppeditires: o.c.ise oc seuss 2 eG Orne s ete ee Erratic:steering:when braking) .....:% 5.10. .3.- a= oe Excessive pitching and/or rolling around corners or

76 73

GUring braking sis ele ss wale Sle ers hate Pere Excessive play or looseness in steering system .............. Excessive tire wear on inside edge ................+-+e+ees

74 80 78

Excessive tire wear on outside edge ..........+-..-.s0eeuee te Hard steering 2.05 \aacveccmartu erg te tah melee a te. ee 69 Steering wheel does not return to center position correctly ...... 70 Rattling or clicking noise in rack and pinion ................-. «81 Shimmy; shake‘orvibration™ ».)Sistc4> sue ao ere nee “eee 68 Suspension:bottoms’...... .240.2. J. 2ae ee Tire:tread:'worn in one place: ..:.. 2.0. woe. dss sc cee ee Vehicle. pulls to. one Side’... ..5 7b net ns ca. Oe ee

ifs) 79 65

Wander or poor steering stability ...........2.....5.-20000Wheel makes a “thumping” noise ............-...0-e eee eeee

72 67

Troubleshooting

23

This section provides an easy reference guide to the more common

problems which may occur during the operation of your vehicle. Various symptoms and their possible causes are grouped under headings denoting components or systems, such as Engine, Cooling system, etc. They also refer to the Chapter and/or Section that deals with the problem. Remember that successful troubleshooting isn’t a mysterious “black art” practiced only by professional mechanics. It’s simply the result of knowledge combined with an intelligent, systematic approach to a problem. Always use a process of elimination, starting with the simplest solution and working through to the most complex — and never overlook the

obvious. Anyone can run the gas tank dry or leave the lights on overnight, so don’t assume that you’re exempt from such oversights. Finally, always establish a clear idea why a problem has occurred and take steps to ensure that it doesn’t happen again. If the electrical system fails because of a poor connection, check all other connections in the system to make sure they don’t fail as well. If a particular fuse continues to blow, find out why — don’t just go on replacing fuses. Remember, failure of a small component can often be indicative of potential failure or incorrect functioning of a more important component or system.

5

Starter motor noisy or excessively rough in engagement

1

Pinion or flywheel gear teeth worn or broken (Chapter 5).

2

Starter motor mounting bolts loose or missing (Chapter 5).

6

Engine starts but stops immediately

1 Loose or faulty electrical connections at coil pack or alternator (Chapter 5).

2

Insufficient fuel reaching the fuel injectors (Chapter 4).

3 Vacuum leak at the gasket between the intake manifold/plenum and throttle body (Chapters 1 and 4).

7 ~~ Oil puddle under engine

1

Oil pan gasket and/or oil pan drain bolt seal leaking (Chapters 1

and 2).

_ Engine and performance —_

Engine will not rotate when attempting to start

1 Battery terminal connections loose or corroded (Chapter 1). 2 Battery discharged or faulty (Chapter 1). 3 Automatic transaxle not completely engaged in Park (Chapter 7) or clutch not completely depressed (Chapter 8). 4 Broken, loose or disconnected wiring in the starting circuit (Chapters 5 and 12).

Starter Starter Starter Ignition OANDMN Starter

LS)

motor pinion jammed in flywheel ring gear (Chapter 5). solenoid faulty (Chapter 5). motor faulty (Chapter 5). switch faulty (Chapter 12). pinion or flywheel teeth worn or broken (Chapter 5).

Engine rotates but will not start

Fuel tank empty. Battery discharged (engine rotates slowly) (Chapter 5). Battery terminal connections loose or corroded (Chapter 1). Leaking fuel eens) fuel pump, pressure regulator, etc. (Chap— oN + er 4). 5 Fuel not reaching fuel injection system (Chapter 4). 6 Ignition components damp or damaged (Chapter 5). 7 Worn, faulty or incorrectly gapped spark plugs (Chapter 1). 8 Broken, loose or disconnected wiring in the starting circuit (Chapter 5).

9 Broken, loose or disconnected wires at the ignition coil(s) or faulty coil(s) (Chapter 5).

3

Engine hard to start when cold

2

Oil pressure sending unit leaking (Chapter 2).

3 ~ Rocker arm cover gaskets leaking (Chapter 2).

4 5

oe

Engine oil seals leaking (Chapter 2). Timing cover sealant or sealing flange leaking (Chapter 2).

Engine lopes while idling or idles erratically

Vacuum leakage (Chapter 4). Leaking EGR valve or plugged PCV valve (Chapters 1 and 6). Air filter clogged (Chapter 1). Fuel pump not delivering sufficient fuel to the fuel injection system oO hapter 4). Leaking head gasket (Chapter 2). Timing chain and/or gears worn (Chapter 2). Camshaft lobes worn (Chapter 2). =NOODRWND

©

Engine misses at idle speed Spark plugs worn or not gapped properly (Chapter 1).

Faulty spark plug wires (Chapter 1). Vacuum leaks (Chapters 1 and 4). Incorrect ignition timing (Chapter 5). or low compression (Chapter 2).

Uneven ahrWN—

10

Engine misses throughout driving speed range

1 Fuel filter clogged and/or impurities in the fuel system (Chapters 1 and 4).

2 3. 4 5 6

Low fuel output at the injector (Chapter 4). Faulty or incorrectly gapped spark plugs (Chapter 1). Incorrect ignition timing (Chapter 5). Leaking spark plug wires (Chapter 1). Faulty emission system components (Chapter 6).

7

Loworuneven cylinder compression pressures (Chapter 2).

1 2 3.

Battery discharged or low (Chapter 1). Fuel system malfunctioning (Chapter 4). Injector(s) leaking (Chapter 4).

8 Weak or faulty ignition system (Chapter 5). 9 Vacuum leak in fuel injection system, intake manifold or vacuum hoses (Chapter 4).

4

Engine hard to start when hot

11.

‘1 2 3

Air filter clogged (Chapter 1). Fuel not reaching the fuel injection system (Chapter 4). Corroded battery connections, especially ground (Chapter 1).

1 2 3

Engine stumbles on acceleration Spark plugs fouled (Chapter 1). Fuel injection system needs adjustment or repair (Chapter 4). Fuel filter clogged (Chapter 1).

24

at

Troubleshooting Incorrect ignition timing (Chapter 5). Intake manifold air leak (Chapter 4). af WP

12

Engine surges while holding accelerator steady

1 2 3. 4

Intake air leak (Chapter 4). Fuel pump faulty (Chapter 4). Loose fuel injector harness connections (Chapter 4). Defective ECM (Chapter 6).

13

Engine stalls

1. 2

Idle speed incorrect (Chapters 1 and 4). Fuel filter clogged and/or water and impurities in the fuel system

18

(Chapters 1 and 4).

Engine electrical system 19

Ignition components damp or damaged (Chapter 5).

4

Faulty emissions system components (Chapter 6).

5 6 7

Faulty or incorrectly gapped spark plugs (Chapter 1). Faulty. spark plug wires (Chapter 1). Vacuum leak in the fuel injection system, intake manifold or vacuum

hoses (Chapter 4).

Alternator drivebelt defective or not adjusted properly (Chapter 1). — Battery terminals loose or corroded (Chapter 1). i Alternator not charging properly (Chapter 5).

Loose, broken or faulty wiring in the charging circuit (Chapter 5).

Engine lacks power 20

4 5 6 7 8

Faulty coil(s) (Chapter 5). Brakes binding (Chapter 1). Automatic transaxle fluid level incorrect (Chapter 1). Clutch slipping (Chapter 8). -Fuel filter clogged and/or impurities in the fuel system (Chapter 1).

9 10

Emission control system not functioning properly (Chapter 6). Lowor uneven cylinder compression pressures (Chapter 2).

1

Emissions system not functioning properly (Chapter 6).

5 Vacuum leak at fuel injectors, intake manifold or vacuum (Chapter 4). 6 Valves sticking (Chapter 2).

Pinging or knocking engine sounds during acceleration or uphill

Incorrect grade of fuel. Ignition timing incorrect (Chapter 5). Fuel injection system in need of adjustment (Chapter 4). Improper or damaged spark plugs or wires (Chapter 1). Worn or damaged ignition components (Chapter 5). Faulty emissions system (Chapter 6). — WDM NOOR Vacuum leak (Chapter 4).

a

Pw Ww

21 aie

2

hoses

22

Engine runs with oil pressure light on

1

Low oil level (Chapter 1).

Faulty alternator or charging circuit (Chapter 5). Alternator drivebelt defective or out of adjustment (Chapter.1). Alternator voltage regulator inoperative (Chapter 5).

Voltage warning light fails to come on when key is turned on Warning light bulb defective (Chapter 12). Fault in the printed circuit, dash wiring or bulb holder (Chapter 12).

Excessive fuel consumption

Dirty or clogged air filter element (Chapter 1). Incorrectly set ignition timing (Chapter 5). Emissions system not functioning properly (Chapter 6). Fuel injection internal parts worn or damaged (Chapter 4). Low tire pressure or incorrect tire size (Chapter 1). = aaron

23

Fuel leakage and/or fuel odor Leak in a fuel feed or vent line (Chapter 4). Tank overfilled.

Evaporative canister filter clogged (Chapters 1 and 6). Fuel injector internal parts excessively worn (Chapter 4).

WOM

Cooling system 24

17.

Voltage warning light fails to go out

Fuel system

Engine backfires

2 Ignition timing incorrect (Chapter 5). 3 Faulty secondary ignition system (Chapter 5). 4 Fuel injection system in need of adjustment or worn excessively (Chapter 4).

16

Battery will not hold a charge

Short in vehicle wiring (Chapters 5 and 12). Internally defective battery (Chapters 1 and 5). — OoahWwnh

1 Incorrect ignition timing (Chapter 5). 2 Faulty or incorrectly gapped spark plugs (Chapter 1). 3 Fuel injection system out of adjustment or malfunctioning (Chapter iQ) 4)

15

Engine diesels (continues to run) after switching off

1 Idle speed too high (Chapters 1 and 4). 2 Thermo-controlled air cleaner heat valve not operating properly (TBI equipped engines only) (Chapter 6). 3 Excessive engine operating temperature (Chapter 3).

3.

14

Idle rpm below specification (Chapter 1). Short in wiring circuit (Chapter 12). Faulty oil pressure sender (Chapter 2). Worn engine bearings and/or oil pump (Chapter 2).

Overheating

1 2

Insufficient coolant in system (Chapter 1). Water pump drivebelt defective or out of adjustment (Chapter 1).

3

Radiator core blocked or grille restricted (Chapter 3).

Troubleshooting Thermostat faulty (Chapter 3). Electric cooling fan blades broken or cracked (Chapter 3).

32

25

Fluid on slave cylinder

Radiator cap not maintaining proper pressure (Chapter 3).

Ignition timing incorrect (Chapter 5).

Slave cylinder seal faulty (Chapter 8).

NOOO

25

Overcooling

33

Air in system (Chapter 8).

Faulty thermostat (Chapter 3). 34 26

Pedal feels spongy when depressed

Unable to select gears

External coolant leakage

Deteriorated/damaged hoses or loose clamps (Chapters 1 and 3). Water pump seal defective (Chapters 1 and 3).

Leakage from radiator core or header tank (Chapter 3). Engine drain or water jacket core plugs leaking (Chapter 2).

Faulty transaxle (Chapter 7). Faulty clutch disc (Chapter 8). Fork and bearing not assembled properly (Chapter 8). Faulty pressure plate (Chapter 8). arhonr— Pressure plate-to-flywheel bolts loose (Chapter 8).

ON

35 27

Np —

Internal coolant leakage

Leaking cylinder head gasket (Chapter 2). Cracked cylinder bore or cylinder head (Chapter 2).

Clutch slips (engine speed increases with no increase in vehicle speed)

Clutch plate worn (Chapter 8). Clutch plate is oil soaked by leaking rear main seal (Chapter 8). QOnm— Clutch

plate not seated. It may take 30 or 40 normal starts for a new

one to seat. 28

Coolant loss

Too much coolant in system (Chapter 1). Coolant boiling away because of overheating (Chapter 3). Internal or external leakage (Chapter 3). — ON Faulty radiator cap (Chapter 3).

29

Poor coolant circulation

1 2 3

Inoperative water pump (Chapter 3). Restriction in cooling system (Chapters 1 and 3). Water pump drivebelt defective or out of adjustment (Chapter 1).

4

Thermostat sticking (Chapter 3).

4 5

Warped pressure plate or flywheel (Chapter 8). Weak diaphragm spring (Chapter 8).

6

Clutch plate overheated. Allow to cool.

36

Grabbing (chattering) as clutch is engaged Oil soaked, burned or glazed linings (Chapter 8).

Worn or loose engine or transaxle mounts (Chapters 2 and 7). Worn splines on clutch plate hub (Chapter 8). + RWONM Warped pressure plate or flywheel (Chapter 8).

37

Fork shaft improperly installed (Chapter 8). Np —

Clutch

Noise in clutch area

38

Faulty release bearing (Chapter 8).

Clutch pedal stays on floor Fork shaft binding in housing (Chapter 8):

30

Pedal travels to floor — no pressure or very little resistance Master or slave cylinder faulty (Chapter 8). Hose/pipe burst or leaking (Chapter 8). Connections leaking (Chapter 8). No fluid in reservoir (Chapter 8).

If fluid is present in master cylinder dust cover, rear master cylinder — anwhp

seal has failed (Chapter 8). 6 If fluid level in reservoir rises as pedal is depressed, master cylinder center valve seal is faulty (Chapter 8). 7 Broken release bearing or fork (Chapter 8).

31.

Fluid in area of master cylinder dust cover and on pedal Rear seal failure in master cylinder (Chapter 8).

yor ho

39

Broken release bearing or fork (Chapter 8).

High pedal effort

—

Fork shaft binding in housing (Chapter 8).

2

Pressure plate faulty (Chapter 8).

Manual transaxle 40

Vibration

1

Rough wheel bearing (Chapter 10).

2 3

Damaged driveaxle (Chapter 8). Out-of-round tires (Chapter 1).

26 4 5

Troubleshooting Tire out-of-balance (Chapter 10). Worn or damaged CV joint (Chapter 8).

47

Transaxle fluid brown or has a burned smell

Transaxle overheated. Change fluid (Chapter 1). 41

Noisy in Neutral with engine running

Damaged clutch release bearing (Chapter 8).

42 aie

2

Noisy in one particular gear Damaged or worn constant mesh gears (Chapter 7). Damaged or worn synchronizers (Chapter 7).

48

General shift mechanism problems

1 Chapter 7 Part B deals with checking and adjusting the shift linkage on automatic transaxles. Common problems which may be attributed to poorly adjusted linkage are: a) Engine starting in gears other than Park or Neutral. b) Indicator on shifter pointing to a gear other than the one actually being used. . c) Vehicle moves when in Park.

2 __ Refer to Chapter 7 Part B for the shift linkage adjustment procedure. 43

Noisy in all gears

1

Insufficient lubricant (Chapter 1).

2 3

Damaged or worn bearings (Chapter 7). Worn or damaged input gear shaft and/or output gear shaft (Chap-

49

pedal pressed to the floor Throttle valve (TV) cable out of adjustment (Chapter 7).

ter 7).

50 44

Transaxle will not downshift with accelerator

Engine will start in gears other than Park or Neutral

Slips out of gear

Starter safety switch malfunctioning (Chapter 7). Worn or improperly adjusted linkage (Chapter 7). Transaxle loose on engine (Chapter 7). Shift linkage does not work freely, binds (Chapter 7).

51

Input shaft bearing retainer broken or loose (Chapter 7). Dirt between clutch cover and engine housing (Chapter 7).

Worn shift fork (Chapter 7).

— OnarhwhDd

45

Leaks lubricant

1

Excessive amount of lubricant in transaxle (Chapter 1).

2

Loose or broken input shaft bearing retainer (Chapter 7).

Transaxle slips, shifts roughly, is noisy or has no drive

in forward or reverse gears There are many probable causes for the above problems, but the home mechanic should be concerned with only one possibility —fluid level. Before taking the vehicle to a repair shop, check the level and condition of the fluid as described in Chapter 1. Correct the fluid level as necessary or change the fluid and filter if needed. If the problem persists, have a professional diagnose the probable cause..

3. Input shaft bearing retainer O-ring and/or lip seal damaged (Chapter 7).

Driveaxles Automatic transaxle

52

Clicking noise in turns

Note: Due to the complexity of the automatic transaxle, it’s difficult for the home mechanic to properly diagnose and service this component. For problems other than the following, the vehicle should be taken to a dealer

service department or a transmission shop. 46 1

Fluid leakage Automatic transmission fluid is a deep red color. Fluid leaks should

Worn or damaged outer CV joint. Check for cut or damaged boots (Chapter 1). Repair as necessary (Chapter 8).

53

Knock or clunk when accelerating after coasting Worn or damaged outer CV joint. Check for cut or damaged boots

not be confused with engine oil, which can easily be blown by air flow to the transaxle. 2 To pinpoint a leak, first remove all built-up dirt and grime from the

(Chapter 1). Repair as necessary (Chapter 8).

transaxle housing with degreasing agents and/or steam cleaning. Drive

54

Shudder or vibration during acceleration

the vehicle at low speeds so air flow will not blow the leak far from its source. Raise the vehicle and determine where the leak is coming from.

Common areas of leakage are: a) Pan (Chapters 1 and 7)

b) Filler pipe (Chapter 7) c) Fluid cooler lines (Chapter 7)

d) Speedometer gear or sensor (Chapter 7)

1 Excessive inner CV joint angle. Check and correct as necessary (Chapter 8). 2 Worn or damaged CV joints. Repair or replace as necessary (Chapter 8).

3. Stickinginner joint assembly. Correct or replace as necessary (Chapter 8).

Troubleshooting

2

J

Brakes Note: a) b) c)

55

Before assuming that a brake problem exists, make sure. . . The tires are in good condition and properly inflated (Chapter 1). The front end alignment is correct (Chapter 10). The vehicle isn’t loaded with weight in an unequal manner.

Incorrect tire pressures (Chapter 1). Front end out of line (have the front end aligned).

Little or no fluid in the master cylinder reservoir caused by leaking calliper or wheel cylinder pistons, loose, damaged or disconnected brake lines

Unmatched tires on same axle. Restricted brake lines or hoses (Chapter 9). Malfunctioning brake assembly (Chapter 9). Loose suspension parts (Chapter 10).

(Chapter 9).

Noise (high-pitched squeal when the brakes are applied)

Excessive front brake disc lateral runout (Chapter 9).

Parallelism not within specifications (Chapter 9).

3

Unevenpad wear caused by caliper not sliding due to improper clear-

ance or dirt (Chapter 9). Defective brake disc (Chapter 9). Rear brake drum out-of-round.

Parking brake does not hold

Suspension and steering systems Note: Before attempting to diagnose the suspension and steering systems, perform the following preliminary checks:

a) oS Check the tire pressures and look for uneven wear. b) Check the steering universal joints or coupling from the column to the steering gear for loose fasteners and wear. Cc see. Check the front and rear suspension and the steering gear assem-

Brake roughness or chatter (pedal pulsates)

1

Brake pedal travels to the floor with little resistance

Parking brake linkage improperly adjusted (Chapter 9).

Vs

2

4 5

64

calipers (Chapter 9).

ter 9).

,

1 Air in hydraulic lines (Chapter 9). 2 _ Master cylinder mounting bolts loose (Chapter 9). 3 Master cylinder defective (Chapter 9).

63

Front disc brake pads worn out. The noise comes from the wear sensor rubbing against the disc. Replace pads with new ones immediately (Chap-

57

Brake pedal feels spongy when depressed

Vehicle pulls to one side during braking

— WOM NOOR Loose brake

56

62

bly for loose and damaged parts. d aS Look for out-of-round or out-of-balance tires, bent rims and loose and/or rough wheel bearings.

65

Vehicle pulls to one side Mismatched or uneven tires (Chapter 10).

Broken or sagging springs (Chapter 10). Front wheel alignment incorrect (Chapter 10). 58

Excessive pedal effort required to stop vehicle

1

Malfunctioning power brake booster (Chapter 9).

2

Partial system failure (Chapter 9).

3 Excessively worn pads or shoes (Chapter 9). 4 One or more caliper pistons or wheel cylinders seized or sticking (Chapter 9). 5 6

Brake pads or shoes contaminated with oil or grease (Chapter 9). Newpads or shoes installed and not yet seated. It will take a while for

the new material to seat.

59

Excessive brake pedal travel Partial brake system failure (Chapter 9). Insufficient fluid in master cylinder (Chapters 1 and 9).

Front — WOM

a for)

brakes dragging (Chapter 9).

Abnormal or excessive tire wear

Front wheel alignment incorrect (Chapter 10). Sagging or broken springs (Chapter 10). Tire out-of-balance (Chapter 10). Worn shock absorber (Chapter 10). Overloaded vehicle. Tires not rotated regularly. — OarwNM 7

fo?)

Wheel makes a “thumping” noise Blister or bump on tire (Chapter 1).

hw —

Improper shock absorber action (Chapter 10).

Air trapped in system (Chapters 1 and 9).

QOnm—

i°2)foe)

60

Dragging brakes

Master cylinder pistons not returning correctly (Chapter 9). Restricted brakes lines or hoses (Chapters 1 and 9). — OnIncorrect parking brake adjustment (Chapter 9).

61

Shimmy, shake or vibration

Tire or wheel out-of-balance or out-of-round (Chapter 10). Loose or worn wheel bearings (Chapter 10). Worn tie-rod ends (Chapter 10). Worn balljoints (Chapter 10). Excessive wheel runout (Chapter 10). Blister or bump on tire (Chapter 1). — oOarhwWND

Grabbing or uneven braking action 69

Hard steering

Malfunction of proportioner valves (Chapter 9). Malfunction of power brake booster unit (Chapter 9). brake pedal mechanism (Chapter 9).

OnBinding

1 Lack oflubrication at balljoints, tie-rod ends and steering gear assembly (Chapter 10).

28

Troubleshooting Front wheel alignment incorrect (Chapter 10).

OM

70

Low tire pressure (Chapter 1).

Steering wheel does not return to center position correctly

75

Suspension bottoms

—

Overloaded vehicle.

rh

Worn shock absorbers (Chapter 10).

3

Incorrect, broken or sagging springs (Chapter 10).

76

Cupped tires

Lack of lubrication at balljoints and tie-rod ends (Chapter 10). Binding in steering column (Chapter 10).

Defective rack-and-pinion assembly (Chapter 10). * Front wheel alignment problem (Chapter 10).

Abnormal noise at the front end Lack of lubrication at balljoints and tie-rod ends (Chapter 1). Loose upper strut mount (Chapter 10). Worn tie-rod ends (Chapter 10). Loose stabilizer bar (Chapter 10).

Loose wheel lug nuts (Chapter 1). Loose suspension bolts (Chapter 10).

Wander or poor steering stability Mismatched or uneven tires (Chapter 10).

Lack of lubrication at balljoints or tie-rod ends (Chapters 1 and 10). Worn shock absorbers (Chapter 10). Loose stabilizer bar (Chapter 10). Broken or sagging springs (Chapter 10).

Front wheel alignment incorrect (Chapter 10). Worn steering gear clamp bushings (Chapter 10).

wWh — WDM OM Oar — NOOR

Front wheel alignment incorrect (Chapter 10). Worn shock absorbers (Chapter 10). Wheel bearings worn (Chapters 8 and 10). Excessive tire or wheel runout (Chapter 10). — akwnhd Worn balljoints (Chapter 10).

77

~+Excessive tire wear on outside edge

1 Inflation pressures incorrect (Chapter 1). 2 Excessive speed in turns. : 3 Front end alignment incorrect (excessive toe-in or positive camber). Have professionally aligned. 4 Suspension arm bent or twisted (Chapter 10).

78

Excessive tire wear on inside edge

1

Inflation pressures incorrect (Chapter 1).

2 Front end alignment incorrect (toe-out or excessive negative camber). Have professionally aligned.

3

Loose or damaged steering components (Chapter 10). .

79

Tire tread worn in one place

Erratic steering when braking urs

Wheel bearings worn (Chapters 8 and 10). Broken or sagging springs (Chapter 10). Leaking wheel cylinder or caliper (Chapter 9). Warped rotors or brake drums (Chapter 9). Worn steering gear clamp bushings (Chapter 10). akrwonh—

2 3

80 mare

74

Excessive pitching and/or rolling around corners

or during braking Loose stabilizer bar (Chapter 10). Worn shock absorbers or mounts (Chapter 10). Broken or sagging springs (Chapter 10). — ROM Overloaded vehicle.

2 3

81.

Tires out-of-balance. Damaged or buckled wheel. Inspect and replace if necessary. Defective tire (Chapter 1).

Excessive play or looseness in steering system Wheel bearings worn (Chapter 10). Tie-rod end loose or worn (Chapter 10). Steering gear loose (Chapter 10).

Rattling or clicking noise in rack and pinion Steering gear clamps loose (Chapter 10).

Chapter 1

Tune-up and routine maintenance

Contents Air filter and PCV filter replacement

........... 0.0 cece eee

Automatic transaxle fluid and filter change Automatic transaxle fluid level check

Eaneny check and’maintenance:

..................

.....2.....

00.00.0000

SIUNISY STC

Manual transaxle lubricant change

Manual transaxle lubricant level check ......................

ee

6

ss... cs ee aeee ete ee ee

8

BR ARENGUTE Ceres ic aicrise icici cieiate wreststeveSi neh tae WA

Beas St On GAtOM

21

29

ee

cag

Positive Crankcase Ventilation (PCV) valve check

ANG FEPlACEIMEMU

19

' Cooling system servicing (draining, flushing and refilling)

.......

Mie san ecescs lie werekemege Mery Ct ye

Powensteeninguluidiievelichecksamusss

nex vale wstetany oyote ates coc athenotseveh Seaaure arale Yq 13

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......................0-.

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31

SParentireranGyachichieckueamesaren

RA XIOIOOOUCHOCK iiraacestore Gylait a bie cues nie tithe oii atteranc’s, Kosh le8 14 Drivebelt check, adjustment and replacement ................ 23 Engine OlandfilterChange? .20...sc. ccs be ee we en cates 12 Evaporative emissions control system check ................ 33 Exhaust Gas Recirculation (EGR) system check ............. 34 BMAUIGeSY STSIMCMOCK ital e sii Wises Kase vialcrmse ana ese a -citecaradele gael a 16 PRRUMICRY IEGIIOC KS ARIA yet yicie atsean heed contac bulSalis wouslio Wiertaele suairans 4 He MNSTNCDIACCIMON tit. ctnaie cae e inltaeiar che seve aoesetetndiele wie arate liens 28 Pa EE TICINO CHG abaya eae cee istec csAtic. See asswlacSeine elewdle e uanne 20 PEELOTAU NeHOMME are syeieta he) ctoser ie,sou apatqtes een elena aretecave. 3)suv 1 ReAMOnAneCeSCHOCUIC mae mbar mare ta create ag ace Giulio ek sees 2

te iene ett

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SEIN G

Meier acne acaconl ea ane

Spar plugreplacementarswmceyepie wan Sree eek ese eae tseee Spark plug coil wire check and replacement ................. Stanensatetviswitehcheckseue. tense nie cise: Sraca ota ieneae aint ae n SusSpensiomandisteenig CHECK We cc aia: six aniieiaien tena ease Throttle Body Injection (TBI) mounting bolt torque check (2.0/2.2 liter four-cylinder engines only) .............. Treranditireipresstire checker... sts sel 2h on elie neo ene de TEM OLAUON ana atetemec cies Si vewacieaeat erie cotrey: take HEicran Seach Mea lidine=up generaliinfonmation, ieesncewee aay ware soaks amet Soe Underhood hose check and replacement .................... Windshield wiper blade inspection and replacement ...........

Specifications

Recommended

lubricants and fluids

Engine oil

Riv SC MMe

itr

sae,

Siiieadh. didlos, elausnl ees edhe'S uals ihe

SG/CC or SG/CD

DISCOS IME rar ve Ante Simimtdiara wyslmishateice atplotn besteyats: baci alas PEECAMOR NSA OM UIC teemtecscianseasiere vate viscemivtelats aca) sue lefyate ManuchtansaxeUDMCAnt ee... his slays ih ede te ee ce eee ayes EROMMIEISOOlAltee ero cit ae teegto oul yak uimnls Sas dare aheltuc edhe. SUPEISCS TLUTGY. 2,nacheer lee anne So eps ae ne COUOAtH mTULC! 5.4S RUNS eeene Rane SRG Reker ete eS to BPVCIESIE CHING UI Chena cote sina tla re epekeig Glee OR ee Mere ds CAMBSSIS AU/SIOZTRSTs GRIER lanes cerca clerics nee ect tLe Mec Oeen

See accompanying chart Dexron Il See your owner’s manual or consult a dealer service department Mixture of water and ethylene glycol-based antifreeze Delco Supreme II or DOT 3 fluid Delco Supreme II or DOT 3 fluid GM power steering fluid or equivalent Multi-purpose, lithium-base chassis grease (meeting specification GM-6031M)

Capacities Engine oil (approximate) 2.0/2.2 liter four-cylinder engines

...............+0 0-2 eee

3.0 qts (2.8 liters)

2.3liter four-cylinder (Quad-4) engine ...6............. 020s

4.0 qts (3.8 liters)

RMON MPM yin eee the a layilar arcia auNeertang aw-atein Werelsda’s @tereid ayes TUISI TAG ~ 2 s)6 3 ]CNBRDRSTSRSOS genet a Mae Sk a a ASIDHMG| QUGTISINA) 5 Bes eka, bb kstesrcaean ene eter one oA Taare Aaa PULOMIAICHKANIGAXIG: a.ferr.rih wee wocoS aes Ghee Aarne a)ataae cn 2 neta » Manual transaxle CMIEDIAGNE! on abn ntdlag ualeer WEESAllesSekePnIE hee JetAria ries mr aEMe PG

USUUPAI) 5

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CABLES! 5 0.olya SRSEROI SME Ia eRe

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4.0 qts (3.8 liters) 13.6 gals (51.5 liters) 8.0 gts (7.5 liters) 8.0 pts (3.8 liters) 5.3 pts (2.5 liters)

ee

4.1 pts (1.9 liters)

okPi cna

Consult a dealer service department

y wunice aN

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LOOK = //~

WEATHER Fale)

LABEL

OG, Noi

+100}44+38

\%,

FOR THIS |{3% 5 |—

‘On’

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ne

IF NEITHER SAE 5W-30 NOR 10W-30 GRADE

OILS ARE AVAILABLE,

Re)

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Index A About this manual, 5

Air cleaner housing assembly, removal and installation, 168 Air conditioning system, general information, 150 Air filter, replacement, 49 Alternator, removal and installation, 183

Antifreeze, general information, 150 Automatic transaxle, 216—228

diagnosis, 217 general information, 217 removal and installation, 224 specifications, 216 Automatic transaxle floor shift control, removal and installation, 223 Automatic transaxle fluid, change, 53 Automatic transaxle fluid filter, change, 53 Automatic transaxle fluid level, check, 39

Automatic transaxle park/lock cable, removal and installation, 223 Automatic transaxle shift cable, replacement and adjustment, 221 Automotive chemical and lubricants, 19

Balljoint, check and replacement, 271 Battery check and maintenance, 40 emergency jump starting, 180 removal and installation, 179 Battery cables, check and replacement, 180 Battery jump starting, 17

Body, 288—304 general information, 288 maintenance, 289 Body identification plate, 7

Body repair major damage, 290 minor damage, 289

Brake and clutch fluid, check, 37 Brake hoses and lines, inspection and replacement, 262 Brake light switch, removal, installation and adjustment, 266 Brake rotor (disc), inspection, removal and installation, 249 Brake shoes (rear), inspection and replacement, 250

354

Index

SS

SSS

SSS

Brake system, check, 47

Disc brake pads, replacement, 245

Brake system bleeding, 263

Door, removal and installation, 299 Door glass regulator, removal and installation, 298 Door handles, removal and installation, 299

Brakes, 244—266 general information, 245 specifications, 244

Bulb, replacement, 312 Buying parts, 10

Cc

Door lock assembly, removal and installation, 296 Door lock cylinder, removal and installation, 299 Door lock striker, removal and installation, 299 Door trim panel, removal and installation, 293 Door window glass, removal and installation, 296 Driveaxle boot check, 45

replacement, 239

Camshaft, installation, 145 Camshaft and bearings, removal and inspection, 132

Camshaft, lifters and housing, removal, inspection and installation, 82

Capacities, 30 Catalytic converter, 202 Charging system

Driveaxles general information, 230, 235 removal and installation, 238 specifications, 229

Drivebelt, check, adjustment and replacement, 51

check, 183 general information and precautions, 182 Chassis electrical system, 305—318 Chassis lubrication, 44 Chemical and lubricants, 19 Circuit breakers, general information, 307

Electrical system, general information, 305 Electrical troubleshooting, general information, 305

Clutch

Electronic Control Module, 193

:

E

description and'check, 230

Electronic Spark Control (ESC) system, 197

general information, 230

Electronic Spark Timing (EST) system, 197

specifications, 229

Emissions control systems, 187—202

Clutch and driveaxles, 229—243 Clutch components, removal, inspection and installation, 233 Clutch fluid level, check, 37 Clutch pedal, removal and installation, 234 Clutch release bearing and lever, removal and installation, 232

Computer Command Control (CCC) system, 187 Computer trouble codes, 191 Console, removal and installation, 302

Constant velocity joints, overhaul, 239 Control arm, removal and installation, 272

Coolant reservoir, removal and installation, 153 Coolant temperature sending unit, check and replacement, 156

Cooling system check, 41

general information, 150 specifications, 149

Cooling system servicing, 54 Cooling, heating and air conditioning systems, 149—162 Crankshaft inspection, 140

installation and main bearing oil clearance check, 144 removal, 135 Crankshaft and bearings, removal, inspection and installation, 69 Crankshaft front oil seal, replacement, 67, 77, 104 Crankshaft pulley, removal and installation, 66 Cruise control, description and check, 318

Cylinder compression check, 115 Cylinder head cleaning and inspection, 129

disassembly, 128 reassembly, 131 removal and installation, 64, 87 Cylinder heads, removal and installation, 100

Cylinder honing, 139

D

general information, 187

Emissions trouble codes, 191 Engine overhaul, 109—148 overhaul general information, 113 overhaul specifications, 109 removal and installation, 117

specifications, 109 Engine (2.0/2.2 liter), 59—72 general information, 60

specifications, 59 Engine (2.3 liter), 73—92 general information, 74—92 specifications, 73—92 Engine (V6), 93—108 general information, 94 specifications, 93 Engine block cleaning, 136 inspection, 137

Engine Engine Engine Engine

coolant level, check, 36 cooling fan, check and replacement, 151 drivebelts, check, adjustment and replacement, 51 electrical systems, 179—186

specifications, 179 Engine identification numbers, 8

Engine mounts, check and replacement, 71, 91, 108 Engine oil, change, 43 Engine oil level, check, 35 Engine overhaul

disassembly sequence, 119 general information, 113 reassembly sequence, 142

Engine rebuilding alternatives, 119 Engine removal, methods and precautions, 116 Evaporative Emission Control System, 199 Evaporative emissions control system, check, 55 Exhaust Gas Recirculation (EGR) system, 197

Diagnosis, 22

check, 55 Exhaust manifold, removal and installation, 63, 76

Disc brake caliper, removal, overhaul and installation, 247

Exhaust manifolds, removal and installation, 98

Index

355

Exhaust system check, 46 removal and installation, 178

Intake manifold, removal and installation, 63, 74, 96 Intermediate axleshaft, removal and installation, 243 Introduction to the Corsica & Beretta, 5

F

J

Fault diagnosis, 22

Jacking and towing, 18

Fluid capacities, 30

Jump starting, 17

Fluid level checks, 35 Flywheel, removal and installation, 89

Flywheel/driveplate, removal and installation, 70, 108 Front end alignment, general information, 286 Front fender, removal and installation, 292 Front fender liner, removal and installation, 291

L Lubricants and fluids, 29

Front hub and wheel bearing assembly, removal and installation, 276 Front stabilizer bar and bushings, removal and installation, 269

Front strut and spring assembly, removal, inspection and installation, 273 Fuel and exhaust systems, 163—178 Fuel filter, replacement, 52

Fuel injection system check, 170 general information, 169

Fuel lines and fittings, repair and replacement, 166 Fuel pressure relief procedure, 164

Fuel pump, removal and installation, 168 Fuel pump/fuel pressure, testing, 164 Fuel system check, 48 general information, 163

specifications, 163 Fuel tank Cleaning and repair, 167 removal and installation, 167 Fuses, general information, 306

Fusible links, general information, 307

H Hazard flasher, replacement, 307 Headlight, removal and installation, 310

Headlight switch, replacement, 310 Headlights, adjustment, 312 Heating system, general information, 150 Hood, removal and installation, 290

Hood latch cable, replacement, 290

M Main and connecting rod bearings, inspection, 142 Maintenance, 29—58

hinges and locks, 290 Maintenance schedule, 34 Maintenance techniques, tools and working facilities, 10 Manual transaxle, 203—215 : general information, 203 removal and installation, 207 specifications, 203 Manual transaxle lubricant change, 54 check, 46 Manual transaxle overhaul, general information, 208 Manual transaxle shift cables, removal and installation, 204, 205 Manual transaxle shift control, removal and installation, 207 Manual transaxle shifter shaft seal, removal and installation, 205 Master cylinder, removal, overhaul and installation, 259

O Oil, change, 43 Oil filter, change, 43 Oil pan, removal and installation, 69, 88, 106

Oil pump removal and installation, 70, 107 removal, inspection and installation, 88 Outside mirror, removal and installation, 303 Oxygen sensor, 196

Horn, check and replacement, 318

Horn relay, replacement, 307 Hydraulic clutch components, removal and installation, 230 Hydraulic clutch system, bleeding, 232 Hydraulic lifters, removal, inspection and installation, 65, 102

Pp Parking brake, adjustment, 264 Parking brake cables, removal and installation, 264 PCV filter, replacement, 49 Piston rings, installation, 143

Ignition coil and module, removal and installation, 181 Ignition switch key lock cylinder, replacement, 310 Ignition system check, 180 general information, 179 Information sensors, 194 | Initial start-up and break-in after overhaul, 148

Instrument panel, removal and installation, 314

Pistons and connecting rods inspection, 139 installation and rod bearing oil clearance check, 146 removal, 134 {

Port fuel injection (PFI), component removal and installation, 173 Positive Crankcase Ventilation (PCV) system, 201 Positive Crankcase Ventilation (PCV) valve, check and replacement, 54 Power brake booster, inspection, removal and installation, 265

SS

356

Index

Power door lock system, description and check, 318 Power steering fluid level, check, 39 Power steering pump, removal and installation, 283 Power steering system, bleeding, 283

T Thermostat, check and replacement, 150

Power window system, description and check, 318

Throttle Body Injection (TBI), bolt torque check, 51 Throttle body injection (TBI), component replacement, 172 Throttle body injection (TBI) assembly, removal

R

Throttle cable, removal and installation, 177 Throttle valve (TV) cable, replacement and adjustment, 219 Tie—-rod ends, removal and installation, 280 Timing chain and sprockets -

and installation, 171

Radiator, removal and installation, 152

inspection,

Radiator grille, removal and installation, 293 Radio, removal and installation, 313 Radio antenna, removal and installation, 314

Rear axle assembly, removal and installation, 280 Rear hub and wheel bearing assembly, removal and installation, 279

Rear lens assembly, removal and installation, 302 Rear main oil seal installation, 146 replacement, 71, 89, 108 Rear shock absorber, removal and installation, 278

Rear springs-and insulators, removal and installation, 278 Rear stabilizer bar, removal and installation, 277 Rear wheel cylinder, removal, overhaul and installation, 258

Rear window defogger, check and repair, 315 Recommended lubricants and fluids, 29 Relays, general information, 307 Repair operations possible with engine in vehicle, 74

Repair operations possible with the engine in vehicle, 60, 94 Rocker arm cover, removal and installation, 60 Rocker arm covers, removal and installation, 94

removal and installation, 68

—

inspection, removal and installation, 105 removal, inspection and installation, 78 Timing chain cover, removal and installation, 68, 104 Timing chain housing, removal and installation, 82

Tire and tire pressure checks, 37 Tire rotation, 46 Top Dead Center (TDC), locating, 116

F

Towing and jacking, 18 Transaxle Converter Clutch (TCCY, 201 Transaxle differential seals, replacement, 224 Troubleshooting, 22

Trunk latch and striker, removal and installation, 300 Trunk lid, removal and installation, 299 Trunk lock cylinder, removal and installation, 300 Tune—up, general information, 35 Tune—-up and maintenance, 29—58 introduction, 30 Tune—-up and routine maintenance, 29—58

Tune-up specifications, 30 Turn signal switch assembly, replacement, 308

Rocker arms and pushrods, removal, inspection and installation, 61, 95 Routine maintenance specifications, 30

U Underhood hose check and replacement, 41

S

Upholstery, maintenance, 289

Safety first, 20 Seat belt buzzer, replacement, 307

Seat belts, check, 52 Seatback latch, check, 52 Seats, removal and installation, 303 Signal flasher, replacement, 307

Spare tire and jack, check, 52 Spark plug, replacement, 56

Spark plug coil wire, check and replacement, 58 Speakers, removal and installation, 313

Starter motor removal and installation, 185

V Valve springs, retainers and seals, replacement, 62, 86, 96 Valves, servicing, 131

Vehicle Emissions Control Information (VECI) label, 9 Vehicle identification numbers, 7 Vibration damper, removal and installation, 77, 103 VIN number, 7

Vinyl trim, maintenance, 289

testing in vehicle, 184 Starter safety switch check, 52

check and replacement, 235

W

replacement and adjustment, 219

Starter solenoid, removal and installation, 186

Washer pump, removal and installation, 316

Starting system, general information and precautions, 184 Steering and suspension systems, general information, 268

Steering gear, removal and installation, 281

Water pump check, 153 removal and installation, 154

Steering gear boots, replacement, 282

Wheel studs, replacement, 286

Steering knuckle and hub, removal and installation, 277 Steering system, general information, 280

Wheels and tires, general information, 286

Steering wheel, removal and installation, 285

Wind shield wiper blade inspection and replacement, 42 Windshield and fixed glass, replacement, 290

Strut cartridge, replacement, 275 Suspension and steering, check, 45

Windshield washer fluid level, check, 36 Windshield wiper motor, removal and installation, 316

Suspension and steering systems, 267—287 specifications, 267

Windshield wiper switch, removal and installation, 316 Wiring diagrams, general information, 318

HAYNES AUTOMOTIVE

MANUALS

GA

Ce tre

NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

ACURA “1776

Integra & Legend all models ‘86 thru ‘90

AMC Jeep CJ - see JEEP (412) Mid-size models, Concord, Hornet, Gremlin & Spirit ‘70 thru ‘83 (Renault) Alliance & Encore all models ‘83 thru ‘87

694 934 :

*1628 274 *1336 1762 704

319 626 241 *1642

AUDI

420

615

4000 all models ‘80 thru ‘87

428 1117

5000 all models ‘77 thru ‘83 5000 all models ‘84 thru ‘88

“1664 *831

AUSTIN

*1727 *345

Healey Sprite - see MG Midget

Roadster (265)

BMW *2020

*2058

all-wheel drive models ‘82 thru ‘92

240

1500 thru 2002 all models except Turbo ‘59 thru ‘77 2500, 2800, 3.0 & Bavaria all models

/

GENERAL MOTORS (829) Buick, Oldsmobile & Pontiac Full-size (Front wheel drive) all models ‘85 thru ‘93 Buick Electra, LeSabre and Park Avenue;

Oldsmobile Delta 88 Royale, Ninety Eight

627

and Regency; Pontiac Bonneville Buick Oldsmobile & Pontiac Full-size (Rear wheel drive) Buick Estate ‘70 thru ‘90, Electra’70 thru ‘84, LeSabre ‘70 thru ‘85, Limited ‘74 thru ‘79 Oldsmobile Custom Cruiser ‘70 thru ‘90, Delta 88 ‘70 thru ‘85,Ninety-eight ‘70 thru ‘84 Pontiac Bonneville ‘70 thru ‘81, Catalina ‘70 thru ‘81, Grandville ‘70 thru ‘75, Parisienne ‘83 thru ‘86 Mid-size Regal & Century all rear-drive models with V6, V8 and Turbo ‘74 thru ‘87

Regal - see GENERAL MOTORS (1671) Skyhawk - see GENERAL MOTORS (766) 552

= Skylark all X-car models ‘80 thru ‘85 Skylark ’86 on - see GENERAL MOTORS

(1420)

Cimarron - see GENERAL MOTORS (766)

296

679 123 430 372 277

310 all models ‘78 thru ‘82

376 368

200SxX all models ‘80 thru ‘83 B - 210 all models ‘73 thru ‘78 210 all models ‘78 thru ‘82

240Z, 260Z & 280Z Coupe ‘70 thru ‘78 280ZX Coupe & 2+2 ‘79 thru ‘83 300ZX - see NISSAN (1137) 510 & PL521 Pick-up ‘68 thru ‘73 510 all models ‘78 thru ‘81

359

Victoria & Mercury Colony Park (‘75 thru ‘87); Ford LTD Crown Victoria & Mercury Gran Marquis (‘83 thru ‘87) Granada & Mercury Monarch all in-line,

773

Ford & Mercury Mid-size,

620 Series Pick-up all models ‘73 thru ‘79 720 Series Pick-up - see NISSAN (771) 810/Maxima all gasoline models, ‘77 thru ‘84

F10 all models ‘76 thru ‘79 Pulsar - see NISSAN (876)

\ 2000 MK I Coupe all models ‘71 thru ‘75 Mercury Capri - see FORD Mustang (654)

236 610 *1668 234

*1477 554 866

*1726 “1779 *349

Astro & GMC Safari Mini-vans ‘85 thru ‘93 Camaro V8 all models ‘70 thru ‘81 Camaro all models ‘82 thru ‘92

Cavalier - see GENERAL MOTORS (766) Celebrity - see GENERAL MOTORS (829) Chevelle, Malibu & El Camino all V6 & V8 models ‘69 thru ‘87 Chevette & Pontiac T1000 ‘76 thru ‘87 Citation all models ‘80 thru ‘85

6 cyl & V8 models ‘75 thru ‘80 Ford Thunderbird & Mercury Cougar (‘75 thru ‘82); Ford LTD & Mercury Marquis (‘83 thru ‘86); Ford Torino,Gran Torino, Elite, Ranchero

pick-up, LTD Il, Mercury Montego, Comet, XR-7 & Lincoln Versailles (‘75 thru ‘86) *654 357 231 649 1670 *1026 *1421 “1418 1338 “1725 *344

Mustang & Mercury Capri all models

including Turbo. Mustang, ‘79 thru ‘92; Capri, ‘79 thru ‘86 Mustang V8 all models ‘64-1/2 thru ‘73 Mustang Il 4 cyl, V6 & V8 models ‘74 thru ‘78 Pinto & Mercury Bobcat ‘75 thru ‘80 Probe all models ‘89 thru ‘92 Ranger/Bronco Il gasoline models ‘83 thru ‘93 Taurus & Mercury Sable ‘86 thru ‘92 Tempo & Mercury Topaz all gasoline models ‘84 thru ‘93 Thunderbird/Mercury Cougar ‘83 thru ‘88 Thunderbird/Mercury Cougar ‘89 and ‘90 Vans all V8 Econoline models ‘69 thru ‘91

GENERAL MOTORS *829 *766

1420

DODGE *723 *1231

Ford LTD & Mercury Marquis (‘75 thru ‘82); Ford Custom 500,Country Squire, Crown

610 all models ‘72 thru ‘76

Sentra - see NISSAN (982) Stanza - see NISSAN (981)

CHEVROLET

449 550

Chrysler & Plymouth Mid-size front wheel drive ‘82 thru ‘93

200SxX all models ‘77 thru ‘79

*1140 *545 *912 *556

625

Aerostar Mini-vans all models ‘86 thru ‘92 Bronco and Pick-ups ‘73 thru ‘79 Bronco and Pick-ups ‘80 thru ‘91 Courier Pick-up all models ‘72 thru ‘82 Ford Engine Overhaul Manual Escort/Mercury Lynx all models ‘81 thru ‘90 Escort/Mercury Tracer ‘91 thru ‘93 Explorer & Mazda Navajo ‘91 thru ‘92 Fairmont & Mercury Zephyr ‘78 thru ‘83 Fiesta all models ‘77 thru ‘80 Ford & Mercury Full-size,

Aries & Plymouth, Reliant ‘81 thru ‘89 Caravan & Plymouth Voyager Mini-Vans

*1671

all models ‘84 thru ‘93 Challenger & Plymouth Saporro all models ‘78 thru ‘83

*2035

Challenger ’67-'76 - see DODGE Dart (234)

Cadillac Rear Wheel Drive all gasoline models ‘70 thru ‘92

CAPRI

FORD

Full-size Front-Wheel Drive ‘88 thru ‘93

402 647 228 525 206 563

699

CADILLAC *751

"1337

124 Sport Coupe & Spider ‘68 thru ‘78 X1/9 all models ‘74 thru ‘80

“1476 788 *880 268 1763 789 *2046 *2021 560 334 754

400 & 600 - see CHRYSLER Mid-size (1337)

MOTORS (1420) Somerset - see GENERAL

Suburbans, Blazers & Jimmys ‘67 thru ‘91 Pick-ups ‘88 thru ‘93 - Chevrolet & GMC, all full-size (C and K) models, ‘88 thru ‘93 S-10 & GMC S-15 Pick-ups all models ‘82 thru ‘92 Sprint & Geo Metro ‘85 thru ‘91 Vans - Chevrolet & GMC, V8 & in-line 6 cylinder models ‘68 thru ‘92

DATSUN

Century (front wheel drive) - see

1551

all V8 & in-line 6 cyl, 2WD & 4WD ‘67 thru ‘87;

094 273

Laser - see DODGE Daytona (1140)

BUICK *1627

Monte Carlo all models ‘70 thru ‘88 Nova all V8 models ‘69 thru ‘79 Nova and Geo Prizm all front wheel drive models, ‘85 thru ‘92 Pick-ups ‘67 thru ‘87 - Chevrolet & GMC,

FIAT

K-Cars - see DODGE Aries (723)

320i all 4 cyl models ‘75 thru ‘83 528i & 530i all models ‘75 thru ‘80

‘69 thru ‘76

Lumina - see GENERAL MOTORS (1671) Lumina APV - see GENERAL MOTORS (2035) Luv Pick-up all 2WD & 4WD ‘72 thru ‘82

CHRYSLER

3/5 Series not including diesel or

276 632 348

Corsica/Beretta all models ‘87 thru ‘92 Corvette all V8 models ‘68 thru ‘82 Corvette all models ‘84 thru ‘91 Chevrolet Engine Overhaul Manual Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons ‘69 thru ‘90

Colt all models ‘71 thru ‘77 Colt & Plymouth Champ (front wheel drive) all models ‘78 thru ‘87 Dakota Pick-ups all models ‘87 thru ‘93 Dart, Challenger/Plymouth Barracuda &

GEO

Valiant 6 cyl models ‘67 thru ‘76 Daytona & Chrysler Laser ‘84 thru ‘89 Omni & Plymouth Horizon ‘78 thru ‘90 Pick-ups all full-size models ‘74 thru ‘91 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups ‘79 thru ‘93 Shadow & Plymouth Sundance ‘87 thru ‘93 Spirit & Plymouth Acclaim ‘89 thru ‘92 Vans - Dodge & Plymouth V8 & 6 cyl models ‘71 thru ‘91

EAGLE

Buick Century, Chevrolet Celebrity, Oldsmobile Cutlass Ciera & Pontiac 6000 all models ‘82 thru ‘93 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza & Pontiac J-2000 & Sunbird all models ‘82 thru ‘92 Buick Skylark & Somerset, Oldsmobile Calais & Pontiac Grand Am all models ‘85 thru ‘91 Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme & Pontiac Grand Prix all front wheel drive models ‘88 thru ‘90 Chevrolet Lumina APV, Oldsmobile Silhouette & Pontiac Trans Sport all models ‘90 thru ‘92

*2039

Metro - see CHEVROLET Sprint (1727) Prizm - see CHEVROLET Nova (1642) Storm all models ‘90 thru ‘93

Tracker - see SUZUKI Samurai (1626)

GMC Safari - see CHEVROLET ASTRO (1477) Vans & Pick-ups - see CHEVROLET

(420, 831, 345, 1664)

(Continued on other side) Talon - see Mitsubishi Eclipse (2097) en EE

your * Listings shown with an asterisk (“) indicate model coverage as of this printing. These titles will be periodically updated to include later model years - consult Haynes dealer for more information.

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320 « (805) 498-6703

HAYNES AUTOMOTIVE

MANUALS

NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information. HONDA 351 1221 2067

160 633 297 1227 *601

NISSAN Accord CVCC all models ‘76 thru ‘83 Accord all models ‘84 thru ‘89 Accord all models ‘90 thru ‘93

Civic 1200 all models ‘73 thru ‘79 Civic 1300 & 1500 CVCC ‘80 thru ‘83 Civic 1500 CVCC all models ‘75 thru ‘79 = Civic all models ‘84 thru ‘91 Prelude CVCC all models ‘79 thru ‘89

1137 *1341 *771 876 *982 *981

SAAB 3002ZX all models including Turbo ‘84 thru ‘89 Maxima all models ‘85 thru ‘91 ~Pick-ups/Pathfinder gas models ‘80 thru ‘93 Pulsar all models ‘83 thru ‘86 Sentra all models ‘82 thru ‘90 Stanza all models ‘82 thru ‘90

247 *980

99 all models including Turbo ‘69 thru ‘80 900 all models including Turbo ‘79 thru ‘88

SUBARU 237 *681

1100, 1300, 1400 & 1600 ‘71 thru ‘79 1600 & 1800 2WD & 4WD ‘80 thru ‘89

OLDSMOBILE HYUNDAI *1552

Bravada - see CHEVROLET S-10 (831) Calais - see GENERAL MOTORS (1420) Custom Cruiser - see BUICK Full-size

Excel all models ‘86 thru ‘93

Y

ISUZU Trooper & Pick-up, all gasoline models

Cutlass all standard gasoline V6 & V8 models ‘74 thru ‘88

Cutlass Ciera - see GENERAL MOTORS (829)

Pick-up, ‘81 thru ‘93; Trooper, ‘84 thru ‘91

JAGUAR

RWD (1551) Firenza - see GENERAL MOTORS (766) Ninety-eight Regency - see BUICK Full-size

961 *1025

Corolla all rear wheel drive models ‘80 thru ‘87 Corolla all front wheel drive models ‘84 thru ‘92

FWD (1551), RWD (1627) Delta 88 Royale - see BUICK Full-size

JEEP *1553 412 *1777

RWD (1551), FWD (1627) Ninety-eight Regency Brougham - see

Cherokee, Comanche & Wagoneer Limited all models ‘84 thru ‘93 CJall models ‘49 thru ‘86 + Wrangler all models ‘87 thru ‘92

LADA *413

1200, 1300. 1500 & 1600 all models including Riva ‘74 thru ‘91

MAZDA

BUICK Full-size RWD (1551) Omega - see PONTIAC Phoenix (551)

Silhouette - see GENERAL MOTORS (2035)

PEUGEOT 663

504 all diesel models ‘74 thru ‘83

626 Sedan & Coupe (rear wheel drive) all models ‘79 thru ‘82 *1082 626 & MX-6 (front wheel drive) all models ‘83 thru ‘91 267 _ ~=CB Series Pick-ups ‘72 thru ‘93 370 GLC Hatchback (rear wheel drive) all models ‘77 thru ‘83 _ 757 GLC (front wheel drive) ‘81 thru ‘85 *2047 MPV all models ‘89 thru ‘93 460 RX-7 all models ‘79 thru ‘85 *1419 RX-7 all models ‘86 thru ‘91

Laser - see MITSUBISHI Eclipse (2097) For other PLYMOUTH titles, see DODGE listing.

T1000 - see CHEVROLET Chevette (449) J-2000 - see GENERAL MOTORS (766) 6000 - see GENERAL MOTORS (829)

346 983 698 697

190 Series all four-cylinder gasoline models, ‘84 thru ‘88 230, 250 & 280 Sedan, Coupe & Roadster all 6 cyl sohc models ‘68 thru ‘72 280 123 Series gasoline models ‘77 thru ‘81 350 & 450 Sedan, Coupe & Roadster all models ‘71 thru ‘80 Diesel 123 Series 200D, 220D, 240D,

1232 555 867

MR2 all models ‘85 thru ‘87

304 *656 *2048

Pick-up all models ‘69 thru ‘78 Pick-up all models ‘79 thru ‘92 Previa all models ‘91 thru ‘93

112 113 322

GT6 & Vitesse all models ‘62 thru ‘74 Spitfire all models ‘62 thru ‘81 TR7 all models ‘75 thru ‘81

159

Beetle & Karmann

238

‘54 thru ‘79 Dasher all gasoline models ‘74 thru ‘81

*884

451

Bonneville Brougham - see Buick Full-size (1551) Catalina - see Buick Full-size (1551) Fiero all models ‘84 thru ‘88 ‘Firebird V8 models except Turbo ‘70 thru ‘81 Firebird all models ‘82 thru ‘92 Full-size Rear Wheel Drive - see BUICK

082 226 084 1029

Ghia all models

Rabbit, Jetta, Scirocco, & Pick-up gas

~

models ‘74 thru ‘91 & Convertible ‘80 thru ‘92 Rabbit, Jetta & Pick-up all diesel models ‘77 thru ‘84 Transporter 1600 all models ‘68 thru ‘79 Transporter 1700, 1800 & 2000 all models ‘72 thru ‘79 Type 3 1500 & 1600 all models ‘63 thru ‘73 Vanagon all air-cooled models ‘80 thru ‘83

Oldsmobile, Pontiac Full-size RWD (1551) Full-size Front Wheel

Drive - see BUICK

Oldsmobile, Pontiac Full-size FWD (1627) Grand Am - see GENERAL MOTORS (1420) Grand Prix - see GENERAL MOTORS (1671) Grandville - see BUICK Full-size (1551) Parisienne - see BUICK Full-size (1551)

240TD, 300D, 300CD, 300TD, 4- & 5-cyl incl. Turbo ‘76 thru ‘85

MERCURY

Corolla Tercel all models ‘80 thru ‘82 Corona all models ‘74 thru ‘82 Cressida all models ‘78 thru ‘82 Land Cruiser all models ‘68 thru ‘82 MK Il all 6 cyl models ‘72 thru ‘76

*1339

Bonneville - see Buick Full-size

MERCEDES-BENZ

j

VW

PONTIAC

FWD (1627), RWD (1551) *1643

636 360 532 313 200

all models ‘83 thru ‘91 Sedan all models ‘71 thru ‘74 Rear Wheel Drive ‘71 thru ‘85 Front Wheel Drive ‘86 thru ‘92 Supra all models ‘79 thru ‘92 all models ‘75 thru ‘79

TRIUMPH

PLYMOUTH

648

TOYOTA Camry Carina Celica Celica Celica Corolla

Delta 88 Brougham - see BUICK Full-size

XJ6 all 6 cyl models ‘68 thru ‘86 XJ12 & XJS all 12 cyl models ‘72 thru ‘85

Samurai/Sidekick and Geo Tracker all models ‘86 thru ‘93

1023 150 935 *2038 1139 361

Cutlass Supreme - see GM (1671)

Delta 88 - see BUICK Full-size RWD (1551) *242 *478

*1626

RWD (1551) *658

*1641

SUZUKI

551

See FORD Listing

Phoenix & Oldsmobile Omega models ‘80 thru ‘84

all X-car

VOLVO 203 129 *270 400 *1550

120, 130 Series & 1800 Sports ‘61 thru ‘73 140 240 260 740

Series Series Series & 7€0

all models all models all models Series all

‘66 thru ‘74 ‘74 thru ‘90 ‘75 thru ‘82 models ‘82 thru ‘88

Sunbird - see GENERAL MOTORS (766) Trans Sport - see GENERAL MOTORS (2035)

MG 111 265

MGB Roadster & GT Coupe all models ‘62 thru ‘80 MG Midget & Austin Healey Sprite Roadster ‘58 thru ‘80

MITSUBISHI *1669

*2022 *2097

Cordia, Tredia, Galant, Precis & Mirage ‘83 thru ‘93 Pick-up & Montero ‘83 thru ‘93 Eclipse, Eagle Talon & Plymouth Laser ‘90 thru ‘94

MORRIS 074 . (Austin) Marina

024

1.8 all models ‘71 thru ‘78

~-Minor 1000 sedan & wagon ‘56 thru ‘71

SPECIAL MANUALS PORSCHE *264

911 all Coupe & Targa models except Turbo & Carrera 4 ‘65 thru ‘89

239

914 all 4 cyl models ‘69 thru ‘76

397

924 all models including Turbo ‘76 thru ‘82

*1027

944 all models including Turbo ‘83 thru ‘89

RENAULT 141 079 097 768 081

5Le Car all models ‘76 thru ‘83 8 & 10 58.4 cu in engines ‘62 thru ‘72 12 Saloon & Estate 1289 cc engine ‘70 thru ‘80 15 & 17 all models ‘73 thru ‘79 1689.7 cu in & 95.5 cu in engines ‘65 thru ‘72 Alliance & Encore - see AMC (934)

* Listings shown with an asterisk (*) indicate model coverage as of this printing. These titles will be periodically updated to include later model years - consult your Haynes dealer for more information.

1479 1654 1667 1480 1762 1736 1763 482 2069 1666 299 393 300

Automotive Body Repair & Painting Manual Automotive Electrical Manual Automotive Emissions Control Manual Autcmotive Heating & Air Conditioning Manual Chevrolet Engine Overhaul Manual GM and Ford Diesel Engine Repair Manual Ford Engine Overhaul Manual Fuel Injection Manual Holley Carburetor Manual Small Engine Repair Manual SU Carburetors thru ‘88 Weber Carburetors thru ‘79 Zenith/Stromberg CD Carburetors thru ‘76

Over 100 Haynes motorcycle manuals also available

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320 « (805) 498-6703

5-94

CARBON

DEPOSITS

NORMAL

Symptoms: Dry sooty deposits indicate a rich mixture or weak

ignition. Causes misfiring, hard

starting and hesitation. Recommendation: Check for a clogged air cleaner, high float level, sticky choke and worn ignition points. Use a spark plug with a longer core nose for greater anti-fouling protection.

OIL DEPOSITS Symptoms: Oily

coating

caused by poor oil control. Oil is leaking past worn valve guides or piston rings into the

combustion chamber. Causes

hard starting, misfiring and hesition. Recommendation: Correct the mechanical condition with necessary repairs and install new plugs.

TOO

HOT

Symptoms: Brown to grayishtan color and slight electrode wear. Correct heat range for engine and operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range.

ASH DEPOSITS Symptoms: Light brown deposits encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfir-

ing and hesitation during acceleration. Recommendation: |f excessive deposits accumulate over a short time or low mileage, install new valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gasoline brands.

Symptoms: Blistered, white insulator, eroded

electrode

and

absence of deposits. Results in shortened plug life. Recommendation: Check for the correct plug heat range, over-advanced ignition timing, lean fuel mixture, intake mani-

fold vacuum leaks and sticking valves. Check the coolant level and make sure the radiator is not clogged.

WORN Symptoms: Rounded electrodes with a small amount of deposits on the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Recommendation: Replace with new plugs of the same heat range.

PREIGNITION

DETONATION

Symptoms: Melted electrodes. Insulators are white, but may be dirty due to misfiring or flying debris in the combustion chamber. Can lead to engine damage. Recommendation: Check for the correct plug heat range, over-advanced ignition timing, lean fuel mixture, clogged cooling system and lack of lubrication.

Symptoms: Insulators may be cracked or chipped. Improper gap setting techniques can also result in a fractured insu-

HIGH SPEED

SPLASHED

GLAZING

Symptoms: Insulator has yellowish, glazed appearance. Indicates that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating. Causes misfiring at high speeds. Recommendation: Install new plugs. Consider using a colder plug if driving habits warrant.

GAP BRIDGING Symptoms: Combustion

lator tip. Can. lead to piston

damage. Recommendation: Make sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine.

DEPOSITS

Symptoms: After long periods of misfiring, deposits can loosen when normal combustion temperature is restored by

an overdue tune-up. At high

speeds, deposits flake off the piston and are thrown against the hot insulator, causing misfiring. Recommendation: Replace the plugs with new ones or clean and reinstall the originals. MECHANICAL

DAMAGE

de-

Symptoms: May be caused by

posits lodge between the elec-

a foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could result in piston damage. Recommendation: Remove the foreign object from the engine and/or install the correct reach plug.

trodes. Heavy deposits accu-

mulate and bridge the electrode gap. The plug ceases to fire, resulting in a dead cylinder. Recommendation: Locate the faulty plug and remove the deposits from between the electrodes.

‘Every i dial based ona complete _ teardown and rebuild

taynes mechanic, Tuy dave) ar-lave, ohotographer with

Chevrolet Corsica

_ —

i

_ Models covered by this manual: cal

diaaes te) g-\(er- r=]ale|Beretta -1987 thru 1995

Haynes Manuals Explain Best: Step-by-step procedures linked to hundreds of easy-to-follow photos Written from ‘“‘hands-on”’ experience . . using common tools Quick and easy troubleshooting sections

Detailed wiring diagrams

.

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;

Color spark plug diagnosis

0

°"38345'01628'"

8

ISBN 1 56392 133 2 |